Review of Integrated Lean Techniques and Ergonomic Analysis to Upgrade Troubleshooting Systems for Process Enhancement

Occupational Health and Safety systems, as well as physical Ergonomics, serve a common goal, which is to eliminate safety-related injuries within production systems. The analysis of potential hazards that could compromise the safety of operations’ employees assists in preventing a high rate of safety-related injuries. Safer processes result in a high output rate and, hence, a profitable business. Focusing on the accuracy of problem solving and failure prediction analysis on new processes could potentially result in zero safety-related injuries, good-quality products, cost reduction, and the elimination of delays within the processes. This research seeks to add more knowledge to the fields of Occupational Health and Safety systems and Total Productive Maintenance by combining lean manufacturing troubleshooting models with Ergonomic analysis, as well as Hazard Identification Risk Analysis, to predict future kaizen projects for businesses. The proposed upgrade to the problem-solving model was developed by evaluating and reviewing the impact of Ergonomic analysis on different production systems. It was found that Ergonomic analysis provides solutions for a more comfortable working environment; hence, the existing troubleshooting model was combined with an Ergonomic exercise. The proposed model is more beneficial to production systems. It could potentially result in zero safety-related injuries, high-quality products, more accurate problem analysis, and more innovation by enabling kaizen projects. The proposed model was applied in the electronics industry, where it resulted in drastic improvements. The old method, which was causing fatigue, was eliminated, and a new machine was designed and prototyped. The new machine assisted the company in this case study in reducing delays, eliminating defects, and reducing costs. Furthermore, the proposed troubleshooting model evaluated an impactful kaizen project, which was the introduction of new technologies that will eliminate the power-up stage.