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Injury Reduction in Automobile Manufacturing

Efforts by ergonomists working at SRI-Ergonomics have resulted in a significant reduction in injuries and their costs within the automotive manufacturing industry.  Our close partnership with Honda, in particular, has allowed us to improve the lives of the employees who are doing this work while also increasing productivity and profitability for their employers.  

Collaborative projects between SRI-Ergonomics and the automotive industry have ranged from addressing the risk of a single job to fully integrating our macroergonomics architecture across all facilities.  A few specific projects are highlighted below.

Door Line Assembly

SRI-Ergonomics partnered with Honda to address the high rates of musculoskeletal disorders (MSDs) that were occurring on one of their door assembly lines.  The outcome of the project was a reduction of 2.45 work-related MSDs every year on this line, as well as a significant increase in productivity.  The $89,000 investment made by Honda, which was divided between workstation modifications and consulting fees, was returned in three months.  Over a five-year period, the increased work efficiency and reduced injury costs that resulted from this project returned  $1.8M ($360,000 per year) to Honda's bottom line, creating a 2023% return-on-investment.

Macroergonomics Integration

In an effort to continue to improve the safety of their workers, Honda asked the SRI-Ergonomics experits to identify and address several ergo-related risks across their North American assembly plants.  Just one year after the implementation of our macroergonomics framework in all facilities, injuries fell by 92.9%.  This drastic reduction in work-related injuries is estimated to have saved Honda $1.7M in direct medical costs for every 100 strains/sprains eliminated.

In addition to the frequency of injuries, Honda was also comitted to reducing the severity of strain and sprain injuries in their North American assembly plants. Six years after the continued integration of our marcroergonomics processes, injury severity (defined as days lost due to injury) had dropped by nearly 88%!