ErgoRisk | Ergonomics Platform

Case study

Optimization on Quality Control & Packaging Workstation

Company: Ege Fren

Challenge

Identifying Ergonomic Risks in Quality Control & Packaging with AI-Powered Video Analysis

During the quality control and packaging process on a workbench, workers were exposed to awkward postures, repetitive movements, and prolonged standing. The task required bending, twisting, and lifting, leading to potential ergonomic risks affecting the neck, lower back, wrists, and elbows.

How Problems Were Identified?

A risk analysis was conducted, revealing the following ergonomic hazards:

Prolonged standing throughout the shift

Frequent forward neck forward bending

Bending and twisting from the waist while picking up and placing materials

Repetitive and awkward wrist postures, particularly during manual tool usage

Why This Was Critical to Solve?

These ergonomic risks lead to:

Increased risk of muscoloskeletal disorders (MSDs)

Reduced efficiency and productivity due to discomfort and fatigue

Increased costs due to medical expenses and absenteeism

Solution

AI-Generated

Improvement & Training

To address these risks, AI-generated improvements & trainings were introduced, focusing on ergonomic workstation design, automation, and employee training

Sit-Stand Stool Implementation

Sit-stand stool introduced to reduce fatigue from prolonged standing. Workers were able to alternate between sitting and standing, improving comfort and endurance

Adjustable Workstation for Optimal Height

There was workstation height issues that forced workers into awkward bending postures. The solution involved installing adjustable-height workbenches to minimize unnecessary forward bending and enhance posture alignment

Optimized Material Handling to Reduce Repetitive Twisting

Optimization to reduce repetitive twisting by repositioning materials for easier access and introducing elevated drop-off zones to minimize bending.

Automation of Manual Tool Use

AI identified manual tool usage as a major contributor to wrist and elbow strain. This led to the implementation of automated fastening tools and standardized ergonomic training to ensure proper hand positioning.

Ergonomic Training for Employees

AI-powered training sessions were introduced to educate employees on proper posture, lifting techniques, and the effective use of ergonomic tools to reduce strain and prevent injuries.

Result

AI-Measured Impact & Outcomes

The AI-powered interventions led to significant improvements in workplace safety, efficiency, and worker well-being.

Key metrics

Workplace Injuries (Back, Neck, Wrists)

Hours of Standing per shift

Bending & Twisting Movements per Shift

Medical Leave Due to MSDs

Production Efficiency

Before Analysis

High injury rate (3.5 incidents per month)

7+ hours of continuous standing

150+ excessive bending/twisting movements per worker

Average 6 sick days absence per workper per year

%85 efficiency rate

After Analysis

Reduced by 65% (1.2 incidents per month)

Alternating sit-stand work, reducing standing time by 50%

Reduced by 40% (now averaging 90 movements per shift)

Reduced to 2 sick days per workper per year

Improved to %95