A Model aimed at Reducing Absenteeism by Redesigning Workspaces at School Supply Companies in the Plastics Industry

The exposure of operators to musculoskeletal disorders (MSDs) due to man-machine work is a factor that is very present in manufacturing companies. This represents a physical integrity risk, causing health consequences and an increase in absenteeism. The objective of this study is to redesign laminating, stamping, inspection and packaging stations under an anthropometric approach with height-adjustable furniture, but also considering Motion Economy by adopting U-shaped production line layouts, and taking advantage of corners and inclination angles of furnishings to maintain better working postures. In addition, to include a new method of transportation and handling of materials based on batch work supported by the insertion of a conveyor belt and Facility Layout Design (FLD) to reduce the distances traveled. The results of the model point to a 44.72% reduction in the absenteeism rate, validated by simulation in Delmia V5 and the use of ergonomic evaluation tools such as the Rapid Upper Limb Assessment (RULA), the National Institute for Occupational Safety and Health (NIOSH) index, and the OCRA Checklist. This study helps minimize the work postures that constitute a dysergonomic risk factor to reduce the high absenteeism rate.