Case study
Company: Hugo Boss
Challenge
Ergonomic Risks in Labeling and Triage Workstation
The labeling and triage process in a textile factory posed serious ergonomic risks for workers, leading to long-term health issues, increased absenteeism, and reduced productivity.
How the problems were identified?
Using computer vision and AI-powered video analysis, the workstation recorded and analyzed worker movements to detect ergonomic risks in real-time. The AI identified:
Repetitive wrist and elbow movements due to manual labeling
Improper wrist posture (excessive flexion) while handling labels
Frequent weight carrying (labeling machine handling) adding physical strain
Why This Was Critical to Solve?
The AI-generated analysis revealed that workers were at high risk of developing long-term musculoskeletal disorders. This led to:
Higher rates of workplace injuries
Increased costs due to medical expenses and absenteeism
Lower efficiency and longer production cycles
Solution
AI-Generated
Improvements & Training
To mitigate these challenges, AI-powered Improvements were implemented, leading to a combination of technological innovation, operational restructuring, and worker training.
1
Automated Labeling Process
Replacing manual labeling with a sensor-based system. This eliminated repetitive wrist movements by automating the labeling process.
2
Eliminating the Old Labeling Machine
The manual labeling machine, identified as a key source of wrist strain, was removed, reducing unnecessary hand movements and strain.
3
Health Screening for New Hires
Pre-employment wrist health assessments to ensure that new employees had the physical capability to perform the job safely.
4
Ergonomic Training for Workers
Employees received AI-recommended training on proper wrist ergonomics and injury prevention, reducing risks in daily operations
Result
AI-Generated
Improvements & Trainings
To mitigate these challenges, AI-powered Improvement & Trainings were implemented, leading to a combination of technological innovation, operational restructuring, and worker training.
Are you struggling to identify and fix ergonomic risks in your facility?
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