Application of New Ergonomic

Tools and Methods to Lean,

Ergonomics and Six Sigma (LESS)

Ben Zavitz, CPE

Ergonomist
General Dynamics Bath Iron Works
207-442-219
Benjamin.zavitz@gdbiw.com

Application of New Ergonomic Tools To Lean, Ergonomics & Six Sigma – ©2012 B. Zavitz & S. Smith
Objective & Agenda of Workshop
• Present some new tools and methods
specifically designed to integrate ergonomics
into Lean Six Sigma systems
• Tools and methods to quantify risk, measure human
performance, determine the impact of solutions, and
demonstrate return-on-investment.

• Operational Human Excellence

• Lean Manufacturing, Six Sigma, Risk Management,
& How Ergonomics fits into it all

Application of New Ergonomic Tools To Lean, Ergonomics & Six Sigma – ©2012 B. Zavitz & S. Smith
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Evolution of Ergonomics
• Ramazinni
• Industrial Revolution
• Agricultural Vs. Mfg based society
• Frederick Taylor, Henry Ford, F. & J. Gilberth
• Human Factors Engineering / Applied Research
• OSHA & Injuries
• What about internal Productivity?
• Doing the same or more amount of work with less
effort and within the confines of the human
musculoskeletal, physiological and psychological
systems.

Application of New Ergonomic Tools To Lean, Ergonomics & Six Sigma – ©2012 B. Zavitz & S. Smith
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Internal Productivity

80% reduction in lifting

capacity as horizontal
distance increases

Application of New Ergonomic Tools To Lean, Ergonomics & Six Sigma – ©2012 B. Zavitz & S. Smith
Boardroom Wants Vs. Safety
• Company Goals:
• Improve efficiency of operations
• Reduce defects related to the quality of
products
• Introduction of new products/services
quicker to market
• Basically – how to do what we do better,
faster and cheaper

• Problem – What do employees want?

Application of New Ergonomic Tools To Lean, Ergonomics & Six Sigma – ©2012 B. Zavitz & S. Smith
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Operational Human Excellence
Future State of Ergonomics
• Facts and data must drive the process
• Align with board room objectives and
demonstrate impact ergonomics has on
company goals:
• Better, Faster, Cheaper and Safer
• Calculate the actual “Value to Operational
Human Excellence” to create “pull” not “push

Application of New Ergonomic Tools To Lean, Ergonomics & Six Sigma – ©2012 B. Zavitz & S. Smith
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Lean
Eliminating “waste or wasteful activities”

Waste of Motion impacts external & internal productivity

How do you find “Waste” related to hidden human
performance issues?
Application of New Ergonomic Tools To Lean, Ergonomics & Six Sigma – ©2012 B. Zavitz & S. Smith
Six Sigma
Uses a robust process know as DMAIC

Application of New Ergonomic Tools To Lean, Ergonomics & Six Sigma – ©2012 B. Zavitz & S. Smith
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Where Do People Fit Into LSS?
 People are biggest source of quality,
productivity, variation and cost.
 Minimizing NVA waste/overburden related to
people, and creating consistent/ repeatable
processes we can improve production, quality,
reduce costs and improve health & safety.

Are You Really World

Class in Ergonomics &
Human Performance?

Application of New Ergonomic Tools To Lean, Ergonomics & Six Sigma – ©2012 B. Zavitz & S. Smith
Lean Ergonomic Six Sigma Tools
Control, Sustain, & Scale Solutions Define The Issues
Best Practices – FORM
Current Injury Data (injuries, costs, rates)
Training & Standard Work Instructions
Design Guidelines Employee Comments/Feedback

Ergo DFM/DFA/DFLSS Production & Quality Issues

Control Plan & Charts

Improve Process Measure The Problem

& Verify Results (Baseline)
Pareto Analysis of Injuries
Solution Impact Chart
B&W of Cycle Time Variation
Action Plan
Ergo Value Stream Map (Risk Map)
Rapid Prototyping
Task Analysis – VA, NVA
Test & Evaluation
Analyze Solutions Link Analysis/Spaghetti Diagram
Ergo Fishbone Ergo Risk Assessment – REBAR
Brainstorm/Opportunity List Process Capability
Impact Analysis – PICK Chart, REBAR, PIPE
Solution Matrices

Application of New Ergonomic Tools To Lean, Ergonomics & Six Sigma – ©2012 B. Zavitz & S. Smith
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Define & Measure Problem
Define P18 2009 Injuries By Body Part

6 120

5 100

4 80

Count %
3 60 Cumulative
Total

2 40

1 20

0 0
Back Arm Wrist Knee Thumb Ribs Neck Hand Foot Finger Elbow

REBAR Scores

Measure

Application of New Ergonomic Tools To Lean, Ergonomics & Six Sigma – ©2012 B. Zavitz & S. Smith
Measure – Task Analysis VA vs. NVA

Application of New Ergonomic Tools To Lean, Ergonomics & Six Sigma – ©2012 B. Zavitz & S. Smith
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Analysis - Fishbone Diagram
Equipment Materials REBAR
Old Tools – High Vibration High
Wrong Consumable
Risk
Metal Quality
Match Poor Tool Maintenance Body Part
Consumable
Upstream Processes Hand- Wrist
To Tool Elbow
•Welding, Bending, Forming
Ergo Risk
Factor

Vibration

Standard Process
NVA steps Training
• finish
• wrong abrasive = scratches • Feeds, Speeds, Pressure
• blend vs. whole
•Over processing = polish apple
Tool Variation / Right Tool
• Upstream processes
• too many options
•Grind sick @ table
Preventative Tool Maintenance
•Grind sink prior to dresser
• daily oiling
• return tools to Tool Crib
Method / Process People

Application of New Ergonomic Tools To Lean, Ergonomics & Six Sigma – ©2012 B. Zavitz & S. Smith
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Analysis - Impact Prioritization
Solutions prioritized based on lean metrics, ergo
impact, cost, resources, operational efficiency

Application of New Ergonomic Tools To Lean, Ergonomics & Six Sigma – ©2012 B. Zavitz & S. Smith
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Improve

Cell View Workstation View

Application of New Ergonomic Tools To Lean, Ergonomics & Six Sigma – ©2012 B. Zavitz & S. Smith
Verify & Control
REBAR Scores
Initial
82% high risk tasks
38% high risk body parts
REBAR Scores

65% Reduction in Risk

40-60% Time Savings
Follow Up
35% high risk tasks
13% high risk body parts

Application of New Ergonomic Tools To Lean, Ergonomics & Six Sigma – ©2012 B. Zavitz & S. Smith
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Summary
 Understanding root cause of ergonomic issues
is key in creating the long-term vision
 Linking ergonomic risk reduction to board room
goals will ensure a long-term “pull”
 Integrating ergo into LSS is truly moving
towards “Operational Human Excellence”
 Take time & effort - results are so worth it

Application of New Ergonomic Tools To Lean, Ergonomics & Six Sigma – ©2012 B. Zavitz & S. Smith
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