Implementing Ergonomics in Six Sigma DMAIC Methodology to improve the overall safety at a workplace

This project applied qualitative ergonomics principles within the Six Sigma DMAIC framework (Define, Measure, Analyze, Improve, Control) to improve workplace safety and reduce manual handling injuries among industrial workers.

A survey of 50 blue-collar workers was conducted to assess ergonomic risks related to repetitive manual handling tasks. The findings revealed that 68% of participants reported lower back pain, making it the most frequently affected body area. Additional analysis showed that poor posture and repetitive bending were the primary contributors to strain.

To address these issues, the project proposed a practical and cost-effective ergonomic intervention: integrating built-in back support belts into workers’ uniform jackets. This design aimed to reduce lower back strain by up to 40%, while improving posture and providing consistent support throughout the workday—without adding visible or physical discomfort.

By combining ergonomics and Six Sigma methodology, the project demonstrated how structured, data-driven improvements can effectively enhance worker safety, comfort, and overall process efficiency, providing a replicable model for ergonomic integration in industrial environments.