Analysis and Recommendations for an Automotive Manufacturing Assembly Station Ergonomic Risk

Warn Automotive is a medium manufacturing company that supplies Tier 1 automotive parts to OEMs. Their newly implemented lines contain automation and opportunities for improvement. Detailed analysis and risk assessment were completed for a station on one of the assembly lines that has had many complaints from operators. After risk tasks were identified, potential solutions are generated by attempting to eliminate, prevent or protect from the risk. The final solution includes Warn approval to begin to validate and test a robotic arm that eliminates an operator lifting task, a tool that takes the required force away from the operator's fingers, and other smaller improvements to the layout or fixture design.