| Summary: | Lean practices in manufacturing involve the elimination of wastes. Seven types of waste have been identified in manufacturing systems, one of which is motion. Motion refers to the extra steps taken by employees to accommodate inefficient layout, defects, reprocessing, overproduction or excess inventory and also inadequate equipment design. Ergonomics is a way of designing workstations, work practices and work flow to accommodate the capabilities of workers. Good ergonomic design will reduce awkward postures or excessive effort during work. In this study, ergonomics analysis was carried out in a manufacturing company, focused on the movement and postures of the workers while doing work as part of the lean exercise taken by the company. Non-value added motions were observed and evaluated using questionnaires, motion time study and also assessed using the rapid upper limb assessment (RULA) tool. The modified Nordic questionnaires were distributed and some workers were taken as samples for the RULA assessment. The results showed that the body region affected by work related musculoskeletal disorders are the low back, upper back and also the shoulder. The RULA score also showed that the operators experienced pain in the neck, trunk and leg. Based on these results, ergonomics intervention can be used as tool in reducing motion through identifying the ergonomic risk factors while doing work. The aims of ergonomics and lean are aligned to eliminate or reduce waste especially non value added movements. The 'waste' motion of ergonomics such as stretching, bending, awkward postures and extensive reaching can, not only contribute to the safety and health of workers but also productivity and efficiency. © IEOM Society International. © IEOM Society International.
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