Case Study in Ergonomics Problem Solving Process at a Beer Distribution Company

The ergonomic problem-solving process is a uniformly consistent approach to address challenges presented in various environments. Steps include: (1) identification, (2) analysis, (3) brainstorm of possible solutions, (4) implementation (prototypes), and (5) evaluation. This process was conducted at a distribution company that delivered beer to commercial establishments. Less than 200 employees worked at the company. The first three steps of the ergonomic problem-solving process were carried out with warehouse and delivery workers. A safety climate survey was administered. Following data collection (delivery and warehouse tasks observations and a safety climate survey), employees participated in a workshop. The first session introduced work design principles (including product quality, customer service, efficiency, decrease risk of injury, and improve quality of work life) and how they aligned with the company’s goals. Concepts were communicated in an interactive setting. During the second session, two separate groups discussed challenges specific to warehouse or delivery workers. Videos gathered during data collection were shared with workers. Researchers facilitated brainstorm sessions to address challenges presented in those videos. Identified challenges included errors in building orders at the warehouse to delivering keg up stairs and around tight spaces. One suggestion included shifting emphasis from individual pick-rates to team accuracy to stress accuracy over speed. Another solution from brainstorming involved standardizing communication policies with clients. This project covered the first three stages of the ergonomics solution development process (identification, analysis, and brainstorming possible solutions). Further collaboration with the company will incorporate the prototype, implementation and evaluation steps.