Applying Ergonomic Techniques to Optimize Supply Chain Efficiency
Date
2025-10-25
Journal Title
Journal ISSN
Volume Title
Publisher
Department of Mechanical and Production Engineering(MPE), Islamic University of Technology(IUT), Board Bazar, Gazipur-1704, Bangladesh
Abstract
Manual material handling in industries often forces workers into awkward and repetitive
postures, leading to musculoskeletal disorders (MSDs), fatigue, and productivity losses. These
ergonomic risks directly impact supply chain performance by increasing cycle times, reducing
throughput, and raising absenteeism. This thesis addresses these challenges by integrating
ergonomic monitoring with supply chain optimization. A wearable ergonomic posture
monitoring device was created to gather real-time joint angle information from the trunk, upper
arm, lower arm, wrist, and neck. The device has inertial measurement sensors, a
microcontroller, data logging, and a buzzer feedback system that warns workers when they are
in dangerous positions. Validation against Kinovea motion analysis software demonstrated an
average accuracy of approximately 97.4%, with a mean absolute error of 1.76°, thereby
affirming its reliability for industrial use. The device, which used RULA as the assessment
framework, showed that industrial tasks at baseline had high risk scores (average RULA 6–7),
but that post-intervention with real-time feedback lowered the scores to medium risk levels
(RULA 3–4). A lever-assisted CAD device was created in addition to monitoring to reduce the
strain associated with handling heavy loads during conveyor-to-pallet transfers. To lessen
lifting effort and trunk flexion, the CAD model incorporates a pivot lever mechanism and roller
tray. According to time-motion analysis supported by the literature, this device could reduce
the average cycle time per box transfer by approximately 35%, from 17.0 seconds to 11.1
seconds. Throughput is therefore anticipated to increase by approximately 17.2%, from 180.34
boxes per hour to 211.38 boxes per hour. The redesigned posture with the lever-assisted device
lowers the RULA score from 7 to 3, confirming both safety and efficiency gains, according to
additional validation from the CATIA V5 simulation. This study shows that ergonomics-based
interventions have quantifiable supply chain benefits in addition to safeguarding worker
health. Ergonomics becomes a strategic enabler of industrial efficiency and sustainability by
decreasing posture risks, reducing cycle times, and increasing throughput. The results offer a
reproducible framework for incorporating human-centered design into manufacturing and
warehouse processes, balancing supply chain optimization with worker well-being.
Description
Supervised by
Prof. Dr. A. R. M. Harunur Rashid,
Department of Mechanical and Production Engineering(MPE),
Islamic University of Technology (IUT)
Board Bazar, Gazipur-1704, Bangladesh
This thesis is submitted in partial fulfillment of the requirements for the degree of Bachelor of Mechanical and Production Engineering, 2025
Keywords
Citation
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