Reducing Ergonomic Risk

This project documents a practical, safety driven ergonomic initiative. By redesigning a force intensive manual operation into a semi-automated, mechanically assisted system, the organization significantly reduced ergonomic risk while maintaining throughput, quality, and long-term flexibility.

Opportunity

A high-volume molded component required excess flash trimmed after welded as part of its manufacturing process. This trimming operation:

  • Was performed with and operator and a electric powered cylindrical knife

  • Required repeated rotational cutting force and sustained grip

  • Was completed tens of thousands of times per year

  • Created elevated ergonomic risk for operators over time

While the process met product-production requirements, it posed long-term safety and sustainability concerns.

Requirements

  • Eliminate operator repeated rotational force and grip

  • Maintain existing cycle time (5–7 seconds per unit)

  • Support high-mid and low volume production for various diameters and lengths

  • Adapt to future product variations without major reinvestment

  • Improve long-term operator sustainability

Solution

A semi-automated trimming press was designed and implemented while eliminating physical effort from the operators.

Key elements include:

  • Trimming Press integrated in place of the old manual trimming cell. Designed to fit within the required process footprint

  • Multiple quick change die-sets designed for consistent material removal with changeover in minutes

  • Tooling designed to be serviced or re-sharpened if necessary

  • Hydra-pneumatic actuation, integrated controls, and safety curtains

  • Operator assisting loading, cycle start, and unloading

Ergonomic, Operational & Business Benefits

By removing force and repetition from the trimming operation, the solution:

  • Eliminated sustained cutting force

  • Reduced hand, wrist, and forearm strain

  • Allowed operators to work in neutral postures

  • Significantly lowered ergonomic injury risk

Rather than relying on training or administrative controls, physical risk was engineered out of the process. In addition to ergonomic improvements, the system delivered:

  • Greater throughput

  • Improved repeatability, reproducibility, and product aesthetics

  • Reduced operator fatigue and variability

  • Enhanced workforce sustainability

Investment

Total installed cost: $XX,XXX
External funding secured: 30% Savings from a state supported automation grant

Leveraging external funding reduced capital exposure while accelerating implementation.

Takeaway

Effective ergonomic improvements occur when physical risk is designed out of the process. This project demonstrates how safety, efficiency, and adaptability can be achieved with a simple design.

We partner with organizations to identify, assess, and eliminate ergonomic risk at the source, while maintaining operational performance.


~ PIO Products LLC