A vehicle components manufacturer was facing significant challenges in their assembly line. Team members were overburdened due to poor ergonomic conditions, leading to workplace discomfort and safety concerns. These issues ultimately impacted product quality and caused production delays.
The manufacturer faced issues in their material handling process. Employees experienced ergonomic overburden, which led to 12 defects per month with potential customer impact, and 16 minutes of daily downtime due to inefficient material handling. Workers had to handle trays 24 times in a cycle. This resulted in four annual discomfort cases. Significantly, one Musculoskeletal Disorder (MSD) incident cost the company over $20,000.
Ergo Copilot provided an automated approach to assess and solve these ergonomic issues. The process of implementing Ergo Copilot was relatively simple. It started with recording the process through a smartphone. After recording, the video of the process was uploaded to the platform. The system automatically measured the height, distances, and estimated lifting force, assessing the current ergonomic condition. Based on this analysis, Ergo Copilot recommended an optimal solution to implement “One Touch Dolly” and “Flow Rack System.”
After the implementation of this new work system, workers were able to load and unload full and empty trays simultaneously. This reduced tray handling movements from 24 to 12 per cycle, easing the excessive ergonomic strain. The process was also streamlined, which gave workers additional time to focus on quality checks.
The implementation of Ergo Copilot delivered immediate results by eliminating 12 monthly defects and reducing tray handling movements by 50%. The system eliminated 16 minutes of daily downtime and resolved the ergonomic issues through improved material handling. No cases of ergonomic overburden have occurred after implementation of Ergo Copilot.
Operating in a precision-intensive sector, a leading vehicle components manufacturer focuses on worker safety and ergonomic efficiency in their assembly operations.
Vehicle Components Manufacturing
Optimize material handling process through improving ergonomic conditions.
Brandin and his team help our customers with setting up the Pathfinder platform and getting up-to-speed on all the features and functionalities, in addition to assisting them with standardizing their processes where needed.
Brandin is a seasoned manufacturing leader, who has spent more than a decade designing and setting up assembly lines in both the US and China, optimizing them, and working with human operators to maximize productivity and quality.
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Andrey co-founded and successfully exited a startup to immigrate to the US. He spent his next eight years building the core data science infrastructure for Amazon’s supply chain planning team, and the CV/ML infrastructure for Microsoft’s HoloLens organization.
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Zeeshan was a scientific leader at Microsoft’s HoloLens division, where he invented AI technologies to assist frontline workers across industries. Earlier, he shipped IoT platforms and visual defect detection software for manufacturers at Siemens and MVTec GmbH.
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Huy led teams of scientists and engineers at NEC and invented technologies for driver assistance systems that are part of 500,000+ Honda cars. He is an inventor on more than 20 US patents, and his research papers are cited by every lab from MIT, Stanford, and CMU to Apple, Google, and Baidu.
