Application Of Ergonomics In A Footwear Production Line: A Case Study Of Nam Cuong Company In Binh Duong

Abstract

The exponential growth of the footwear manufacturing industry has raised concerns about worker health, safety, and productivity. The purpose of this study is to address the ergonomic challenges encountered in footwear production using the case study of Nam Cuong Company in Vietnam. The labor-intensive manufacturing process includes repetitive motions, non-neutral postures, material handling, and inadequate workflow design, all leading to musculoskeletal disorders and poor performance. The study takes a mixed quantitative and qualitative approach. Current conditions at four key workstations are assessed using ergonomic assessment tools RULA, REBA, and MTM-1, which reveal numerous high-risk factors. Targeted solutions are proposed, such as equipment redesign, procedure modifications, and supplementary aids. The solutions have been piloted, and a comparison of pre- and post-analysis results shows significant improvements, with RULA and REBA risk reductions of 2 to 8 points, and make the total TMU needed for each workstation reduce significantly. The study emphasizes the advantages of incorporating ergonomics into manufacturing, with simple improvements significantly reducing injury risks and increasing productivity. This provides a framework for addressing common ergonomic challenges in footwear production using structured evaluation and participatory, human-centered design.