Survey-Guided Change in Ship Design and Production: Prospects and Limitations

http://deepblue.lib.umich.edu/bitstream/2027.42/116046/1/39015075508526.pd

Lean job design and musculoskeletal disorder risk: A two plant comparison

This study examined the relationship between lean job design and work-related musculoskeletal disorder (WMSD) risk factors. Repetition, force, and posture were assessed for a sample of 56 production jobs across departments at a lean automobile-manufacturing plant and compared to 56 similar jobs at a traditional automobile-manufacturing plant. The results showed greater productivity in the lean plant: less waiting ( p = .006) and walking ( p < .001); and greater repetition exposure ( p = .001). The mean rating for repetition was 5.5 in the lean plant, compared to 5.0 in the traditional plant based on the Latko (1997) hand activity level scale. However, the lean plant had significantly lower peak hand force ratings ( p = .01). When examining force and repetition combined, the lean plant had a lower percentage of jobs above the American Conference for Governmental Industrial Hygienists (ACGIH)-recommended Threshold Limit Value (TLV ® ). The findings suggest that lean manufacturing does not necessarily increase workers' risk for WMSD injuries. © 2009 Wiley Periodicals, Inc.Peer Reviewedhttp://deepblue.lib.umich.edu/bitstream/2027.42/63064/1/20159_ftp.pd

Institutional conformity and technology implementation: A process model of ergonomics dissemination

This paper examines the process of implementation of work-place ergonomics within thirteen plants of the largest division of an automobile manufacturing firm. The process began as plants reacted with varying degrees of conformance to institutional pressures to utilize ergonomics in job design. While all thirteen plants to some degree "adopted" an ergonomics program, varied conformity reactions were manifested in different internal processes which in turn ledto different types and levels of implementation. A grounded theory approach was used to build an overall process model that encompasses all plants' processes. Based on the model, ergonomics adoption is viewed as a value-laden process. The internal organizational consequences are then discussed in terms of contrasting types of internal goals, strategic structures, and implementation approaches. Theoretical as well as practical implications of the model are presented. A new direction for future research in the field of technology adoption and implementation is proposed.Peer Reviewedhttp://deepblue.lib.umich.edu/bitstream/2027.42/29995/1/0000362.pd

Impacts of programmable manufacturing technology: A review of recent studies and contingency formulation

This paper reviews the literature on the social impacts of programmable manufacturing technology (PMT). Several perspectives on the social impact of technology are identified ranging from simple additive models that view technology as having a set of individual and independent causal impacts to a contingency perspective which views the impact of technology as dependent on technical and organizational characteristics. The paper statistically summarizes 30 empirical studies within the 1986-1990 period and finds common trends in findings as well as contradictory evidence. The common trends are that PMT tends to lead to more organic organizations, but also meets with negative employee attitudes, stress, and perceptions of reduced job security and mobility. The contradictory evidence is that most studies report simple, additive effects, while a substantial portion find that the impacts depend on a wide range of contingency variables. The authors argue that simplistic views of PMT as being a homogeneous set of technologies with uni-directional non-contingent social impacts is neither realistic nor useful. A number of future research directions in this area are suggested.Peer Reviewedhttp://deepblue.lib.umich.edu/bitstream/2027.42/30599/1/0000236.pd

Panel data and models of change: A comparison of first difference and conventional two-wave models

The method of first differences as an approach to modeling change is described and it is compared to more conventional two-wave panel models. Substantial advantages are found to the first-difference approach, especially if there are unmeasured, unchanging predictor variables in the model. It is also argued that there are substantial problems in the interpretation of results from the conventional two-wave models. Some of the analytic results are illustrated with a number of applications to the area of stressful life events.Peer Reviewedhttp://deepblue.lib.umich.edu/bitstream/2027.42/25740/1/0000300.pd

The strengths and limitations of lecture-based training in the acquisition of ergonomics knowledge and skill

A common approach to training designers of workplaces to incorporate ergonomic considerations in their designs is a two- to five-day course based primarily on lectures by experts. A quiz, designed to test the acquisition of ergonomics factual knowledge and skill in judging the degree of physical stress in various job configurations, was given to 147 participants before and after four days of a five-day short course based principally on lectures by university faculty and staff. The major findings were as follows. First, there was a considerable lack of factual knowledge and a high level of error in judging the level of stress prior to the training. Second, the training increased participants' factual knowledge but had little impact on their ability to accurately judge levels of stress in slides depicting real work situations. Third, participants' knowledge and skills before the training and their improvement as a result of the training were unrelated to prior education or training in ergonomics or experience with repetitive, manual work. These results are interpreted in light of prior research on design of effective health and safety training.Peer Reviewedhttp://deepblue.lib.umich.edu/bitstream/2027.42/28698/1/0000518.pd

A comparative analysis of participatory ergonomics programs in U.S. and Japan manufacturing plants

The use of a participative approach to ergonomics is growing in countries throughout the world. This paper compares and contrasts Participatory Ergonomics programs in two U.S. and two Japanese manufacturing plants. All four programs focused on the redesign of repetitive manufacturing jobs to reduce physical stress on workers. In all four cases, this traditional ergonomics concern was addressed in a non-traditional way-involving broad participation of many manufacturing functions who worked together as an ergonomics team and direct input from operators whose jobs were redesigned.The participatory ergonomics programs were successful in making significant numbers of job changes in both countries. A comparison of the ergonomics programs across countries revealed some significant differences in structure and process. An overarching difference was in how participation was managed. In the Japan cases, participation was a carefully controlled process by which upper management and staff specialists worked through first-line supervisors to get input from workers meeting in quality (or safety) circles. In the U.S., multi-functional and multi-level task forces (including union and worker representatives) were formed and operators were invited to meetings to give input. The U.S. plants gave the task force a great deal of autonomy and virtually all decisions were group decisions. The differences suggest that effective participatory ergonomics programs can take many forms. The best program for any particular plants in differing countries depends on their own unique history, structure, and culture.Peer Reviewedhttp://deepblue.lib.umich.edu/bitstream/2027.42/27983/1/0000416.pd

Applying value stream mapping to eliminate waste: a case study of an original equipment manufacturer for the automotive industry

Since its beginning, lean manufacturing has built a worldwide reputation based on results related to production improvement and cost reduction in several companies. This management philosophy focuses on customer value creation through the elimination of production wastes. Lean methods and techniques have spread their scope from the automotive industry to a wide range of industries and services. This article presents a case study that describes the use of the lean tool value stream mapping in the production process of automotive parts for a major automotive company. At the beginning of the project, relevant data from the process were collected and analysed. Subsequently, the initial process was mapped, the related wastes were identified, and then future processes were mapped and financial results were estimated. The proposals were presented on kaizen meetings, the action plan was discussed and the decision regarding which option to choose was taken. Consequently, the Cycle Time and the level of the workforce were reduced, the process was improved and savings were obtained