Ergonomic intervention for enhancing productivity and reducing musculoskeletal disorders in water wall panel forming operations: a case study

D. Dinagaran, K.R. Balasubramanian, S.P. Sivapirakasam and N. Prasanna

International Journal of Industrial and Systems Engineering, 2026, vol. 53, issue 4, 522-544

Abstract: This study delves into a practical project aimed at fortifying preventive measures against MSDs to ensure the safety of workers. Focused on a water wall (WW) panel forming machine, the project addresses the need for machine setup changes when adjusting the pitch of panel requirements. The current changeover method is associated with weld defects such as fin twist, spatter, weld off line, and undercut. This paper meticulously investigates the root causes of these weld defects and explores the factors contributing to worker fatigue. Employing statistical quality tools, a comprehensive solution is formulated. The developed method not only successfully diminishes worker fatigue but also achieves a remarkable 60% reduction in cycle time, resulting in substantial cost savings of INR 840,000. The initiative significantly mitigates weld defects, enhancing overall operational efficiency. The findings and recommendations have practical applications for firms seeking to enhance safety measures and operational efficiency.

Keywords: ergonomics; musculoskeletal disorders; MSDs; water wall panel welding; occupational safety. (search for similar items in EconPapers)
Date: 2026
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