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The Ergonomic Evaluation and Improvement of a Cable Forming Process: A Case Study

Since 1986, twelve (12) injuries and illnesses had occurred among cable formers in several shops of a major telecommunications equipment manufacturer resulting in significant lost time and restricted days. The process engineer, supervisor, plant ergonomist, production associates, and maintenance personnel analyzed the problem elements of the job and developed possible solutions. Ergonomic training, repair of the existing boards, a new cable board design, anti-fatigue mats, step stools, and new scissors were implemented. Significant improvements were realized in employee morale and board set-up time. The degree of musculoskeletal stress suffered by these workers was also reduced.