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Ergonomics workshop: using lean thinking to reduce manual material handling injuries

A free breakfast workshop

Friday, May 6, 2016
8:00 AM – 10:00 AM

BSI Offices (formerly EORM)
4 North 2nd Street, Suite 1270
San Jose, CA

Attendance is limited
RSVP by Wednesday, May 4

How lean thinking, planning and problem solving can help align your purpose, processes and people to effectively address ergonomic risks

Lean problem solving can be an effective adjunct to traditional ergonomic assessment tools, providing a proven, structured approach to understanding the processes and practices that create risk and cause injuries. Collaborative identification of ergo “wastes”, root cause analysis, Lean tools and diagrams,  and action plans are all Lean techniques that organizations can employ to drive improvement in their ergonomics programs.

This workshop will focus on Lean planning and thinking and how to influence change within an organization to reduce ergonomics injuries resulting from manual material handling tasks. We will show you how to apply Lean thinking to some real life examples of common ergonomics problems. And then in a hands-on session you will start using a Lean approach and tools to address a current ergonomics problem in your own organization.

What you will learn

Understand Lean concepts of structured, collaborative problem solving and root cause analysis and how they can be used to solve safety problems

  • How to create and write a defined problem statement with examples
  • Lean tools, their purposes, and examples (A3s, Process Flow Maps, and Value Stream Maps)
  • How to better understand your current state with Lean tools and diagram types
  • Conducting root cause analysis
  • Developing and plotting countermeasures
  • Developing and implementing action plans
  • What to do if you  get stuck

Plus, we’ll look at specific types of material handling risks – high or heavy material weights, awkward postures, repetitive motion and lifting, high-force pushing and pulling – and explain how to use Lean tools to identify ergo “wastes”

  • Unnecessary materials handling
  • Unnecessary motion (walking, reaching, etc)
  • Overproduction: too many cycles
  • Over-processing: poor tool choice or design
  • Defects: increased need for production cycles & rework

Bring your own ergonomics challenge

In a working session you'll start to map out a challenge you are currently having at your site and start to think through how you can create an A3 – the most fundamental Lean problem solving tool.

Challenge to bring:

  • A problem that you have been working on for a period of time that you feel is "stuck" or "challenging to move forward"
  • One that may need buy in or support from multiple departments

What you will do in the working session:

  • Create a defined problem statement
  • Start to outline the data and facts you have about your problem
  • Start to develop a list of actions to take when you get back to your facility

When you're done, you'll leave with a rough draft of an A3 to get you started on your problem solving journey. 


Check-in, breakfast served
8:00 – 8:15 AM

8:15 - 9:45 AM

9:45 - 10:00 AM

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