INTEGRATING LEAN MANUFACTURING AND ERGONOMICS FOR SUSTAINABLE WORKFORCE EFFICIENCY IN THE ERA OF INDUSTRY 5.0

Abstract

Background Industry 5.0 emphasizes humancentric, resilient production, yet lean transformations can inadvertently raise musculoskeletal risk if ergonomics is not embedded. We evaluated an “ErgoLean” approach that integrates participatory ergonomics into valuestream improvement to test whether wellbeing and operational performance can improve together. Methods: We ran a pragmatic before–after field study with 130 matched operators on manual/hybrid workstations. The intervention combined annotated valuestream mapping (with steplevel RULA/REBA/HAL indicators), codesign workshops, and piloted workstation/flow changes (adjustable fixtures, part presentation, lighting/visual aids, errorproofing, and microbreaks) institutionalized through daily management. Outcomes were measured preintervention and after stabilization: ergonomic exposure (RULA, REBA, HAL; composite 0–1 index), Nordic Musculoskeletal Questionnaire (NMQ) discomfort index, workplace organization (5S audit), singlepiece cycle time, aggregated defect rate, and Work Ability Index (WAI). Paired ttests assessed withinperson change; a 2×2 chisquare compared defect rates; effect sizes used Cohen’s d_z. Results: Ergonomic exposure decreased across all instruments: RULA −0.88 (−18.7%), REBA −1.29 (−17.1%), HAL −0.76 (−14.9%), and composite −0.040 (−7.8%), all p < 10⁻¹². NMQ discomfort declined −0.88 (−17.2%; p ≈ 1.6×10⁻³²). Workplace organization improved +12.02 points on 5S (+19.2%; p ≈ 8.3×10⁻⁵²). Flow accelerated with cycle time −5.09 s (−9.8%; p ≈ 2.0×10⁻⁴³) and narrower dispersion. Quality improved concurrently: defects fell from 1.845% to 1.158% (risk ratio 0.63, 95% CI 0.54–0.73; χ² ≈ 39.2, p ≈ 3.9×10⁻¹⁰). WAI increased +1.62 (+4.6%; p ≈ 9.7×10⁻³²). Effect sizes were large for most endpoints (e.g., d_z ≈ 1.84 for cycle time; 2.22 for 5S; 1.59, 1.54, and 1.36 for RULA, REBA, HAL; 1.41 for NMQ; 1.38 for WAI). Conclusions: Embedding ergonomics into valuestream design and governance produced sizeable, precise, and directionally consistent improvements in exposure, symptoms, organization, flow, quality, and perceived work ability supporting joint optimization of wellbeing and performance rather than a tradeoff. The ErgoLean pattern offers a practical pathway to humancentric resilience in Industry 5.0 settings.

Keywords: ErgoLean; Industry 5.0; participatory ergonomics; valuestream mapping; RULA; REBA; HAL; Nordic Musculoskeletal Questionnaire; 5S; cycle time; defect rate; Work Ability Index; humancentred manufacturing; lean.