ABSTRACT
Production Ergonomics is an expanding area within General Motors (GM) and the automotive industry as a whole. In the United States, GM has agreed with the Union of Automotive Workers an Ergonomics Process implementation schedule until 1996 and has also expanded its Manufacturing Ergonomics Group. In Europe, the major influence is the implementation of ‘Lean Production’ techniques such as GM Europe’s own , ‘Quality Network Production System’ (QNPS). Production Ergonomics is a key element within QNPS, influencing all other aspects of the system. It aims to protect workers and save money by reducing lost time work injuries and related compensation claims and by
increasing effective working and quality by improving the workplace, tooling and so on. The Ellesmere Port Plant builds up to 120,000 Vauxhall and Opal Astras per year. In
order to achieve this figure the Trim conveyor must run at over 40 units per hour, a cycle time of 90 seconds per station. The task selected for this study-the fitting of the vehicle steering rack assembly to the bulkhead and steering column-is acknowledged by both unions and management as being a problem. The task involves the operator reading the vehicle build sheet, collecting the correct rack, positioning the rack, connecting the rack to the column and finally securing the two nuts and two bolts using a pneumatic wrench. The fitting of the steering rack is a critical safety operation and therefore must be carried out to a strict specification. Medical data from the company doctor in relation to this task showed that of 34 eligible operators, 15 had at some time reported some form of strain a total of 29 times. The most common complain was lower back strain of which there were 9 followed by 6 reports of shoulder/arm strains. Co-operation for the study was received from the QNPS group, the Safety Department, the Medical Department and Trades Union Safety Representatives.
