Application of TRIZ Methodology for Ergonomic Problem Solving in a Continuous Improvement Environment

This paper discusses a case from an automotive industry plant where ergonomic problems were identified corresponding to inadequate postures resulting from operations performed above the workers' head height. Company's economic situation didn't allowed to consider the automation of the operation despite the recognized need to reduce or, ideally, to eliminate the risk to operators. In this context the use of the TRIZ methodology offers an opportunity to identify potential solutions. Therefore, the TRIZ's Su-Field Analysis was used, with the support of an adapted Contradiction Matrix. This approach allowed obtaining a more structured solution, combining Ergonomics with Lean management principles. The outcome of implementing the proposed solution was the elimination of wastes and the improvement of workplaces' ergonomic quality. Furthermore, the study provided some insights on ways of eliminating or reducing existing Occupational Safety issues in the near future.