A different perspective in participatory ergonomics in product development improves assembly work in the automotive industry

This paper describes a case study of a product development process in a bus manufacturing company. The company's design and chassis production were separated from the design and production of the body. A participatory ergonomics approach was used that gathered a group of designers and production engineers from the different plants, including also ergonomics researchers. The group used different methods to improve the product design of the new chassis with respect to the productivity and ergonomics of the assembly process. Beside analyses of running chassis production, simulations were made by experienced workers using prototypes of new chassis and were complemented with computer manikin analyses. The participatory ergonomics approach used resulted in re-designs of the new product, which improved the efficiency and ergonomics of the assembly operations. The conclusion is that this different participatory ergonomics approach, termed participatory ergonomics design, PED, together with the other methods used, has a potential for facilitating communication and co-operation. The approach has a potential to improve assembly productivity and ergonomics and offer a better understanding among product designers and production engineers in product development processes. Relevance to industry The approach of participatory ergonomics design—PED—and methods used offer industrial companies an opportunity to improve design work, production and ergonomics. Using this approach early in the product design process, can provide benefits as problems can be decreased in later stages of production design and production.