ABSTRACT
Variability can be defined as the inherent instability of any type of process. In manufacturing settings, some efforts in reducing process variability have been developed, but zero variability seems to be, so far, an infeasible target. Ergonomic studies have been showing that workers are usually the ones responsible for residual variability. However, it can have impact over the safety of workers. The main purpose of this paper is to demonstrate that the need for managing residual variability in addition to putting the workers in a position of transgressors, it also exposes them to unforeseen risks. To achieve that, three examples of variability situations are described. The main method applied was the Ergonomic Analysis of Work Activity. It is argued that there is the need for a multidisciplinary approach, including not only OH&S professionals, but also human resources and engineering designers, to promote safety during process variability.
