Addressing OSH challenges in non-standardized work practices in small-scale FMCG units by introducing context-specific ergonomic pouch/sachet cutting apparatus

Article type: Research Article

Authors: Singh, Gurdeep^{; 1} | Karmakar, Sougata^{; *}

Affiliations: Department of Design, Indian Institute of Technology (IIT) Guwahati, Guwahati, Assam, India

Correspondence: [*] Address for correspondence: Dr. Sougata Karmakar, Professor, Department of Design, Indian Institute of Technology (IIT) Guwahati, Guwahati-781039, Assam, India. Tel.: +91 361 2582464; Fax: +91 361 2690762; E-mails: [email protected], [email protected]. ORCID: 0000-0001-9649-0865.

Note: [1] ORCID: 0000-0003-3596-1883.

Abstract: BACKGROUND: The FMCG manufacturing industry in industrially developing countries operates in a manual or semi-automatic setup, employing a vast labor force. Several non-standardized work activities prevail on the FMCG shop floor and remain prone to safety-related risks involving repetitive motions, forceful exertions, and awkward postures. Among those, the rework of defective pouches/sachets is an unsafe activity of prime concern. It is prone to minor nicks, cuts, and injuries due to inadequate tools being used. It involves sharp cutters/blades and extensive forceful manual hand squeezing, which leads to drudgery and safety concerns. There lies the lack of standardized tools/apparatus for rework activity, and efforts towards its mitigation are required. OBJECTIVE: Current research aims to address occupational safety-related issues in non-standardized rework activity in small-scale FMCG units through an innovative product design approach. METHODS: An ergo-audit was conducted in eight small-scale FMCG units to identify the prevailing ergonomic stressors and safety concerns. The most critical area of concern, i.e., rework activity, was chosen through card-sorting sessions and discussions held with the stakeholders. An appropriate context-specific apparatus was designed/developed to ensure better safety and occupational health utilizing a systematic product design method involving three phases: initial field survey, design and development, and field trials. RESULTS: The apparatus, which was developed and factory-trialed, was evaluated for productivity improvement and ensuring user compatibility from various human factors’ perspectives. CONCLUSION: In field trials, the developed apparatus was found effective in mitigating safety concerns and various ergonomic stressors associated with FMCG rework.

Keywords: Safety, hazard control, OSH in FMCG, human factors, ergonomic stressors, product design, innovation

DOI: 10.3233/WOR-240096

Journal: Work, vol. 79, no. 3, pp. 1269-1290, 2024