Identification of Ergonomic Issues in the Assembly Line and Improving Ergonomics by Various Engineering Controls

Abstract

This project aims to identify ergonomic issues within the assembly line at the Royal Enfield manufacturing plant and recommend engineering-based solutions to reduce worker strain and improve overall safety. The primary objective is to determine whether existing workstation layouts, manual handling tasks, and operational postures contribute to musculoskeletal disorders (MSDs) such as lower back pain, shoulder strain, and repetitive motion injuries. To assess ergonomic risks, two standardized tools were employed: RULA (Rapid Upper Limb Assessment) to evaluate stress on the upper limbs, and REBA (Rapid Entire Body Assessment) to analyze whole-body postural load. High scores from both assessments across several stations clearly indicated the presence of significant ergonomic hazards. Major risk factors included manual lifting of heavy components, awkward postures involving bending and reaching, and repetitive motions required in cable routing and small-component assembly. The study found that the most effective method to reduce these risks is the implementation of engineering controls, which directly improve the physical work environment. Recommended interventions include introducing mechanical lifting aids for heavy parts such as the fork and front wheel, redesigning and height-adjusting workstations, organizing tools within optimal reach zones, and improving workflow layout to minimize unnecessary movement. These changes can substantially decrease biomechanical stress and enhance operator comfort. Secondary administrative measures job rotation, ergonomic training, and scheduled stretching are suggested to support long-term injury prevention but are insufficient without engineering improvements. Overall, the findings conclude that several assembly line tasks carry high ergonomic risk, making immediate engineering interventions essential for improved safety, OSHA compliance, and sustainable productivity.