What started as a Lean6Sigma (L6S) project to increase special packing production at the Bucyrus Distribution Center ended up improving associate ergonomics.

An L6S team from the Bucyrus Bearing Plant and Distribution Center in Bucyrus, Ohio, started a yellow-belt project last November. Comprised of Andy Conger, electrical engineer, Jeff Haldeman, senior quality analyst, and team leader Victoria Zeits, senior mechanical engineer, the group time studied the special packing area. They found the corrugated box-packing task had the highest cycle time at 2.03 minutes per box.

“The L6S core group gathered critical input from associates who work in special packing,” said Victoria. “We quickly concluded the main problem was box placement. The corrugated boxes sat on a packing bench at shoulder height, forcing many associates to lift parts up to neck level for packing.”

To improve associate posture, the team chose to modify one of 11 benches, dropping it a total 12 inches. After time studying the process again, the packing cycle time decreased to 1.49 minutes per box, a 15 percent production increase.

“It made such a big difference for associates, and they began asking to work on that bench,” she said. “Under L6S guidelines, we’re supposed to test a solution for three months, but that made no sense ergonomically. So, with the plant manager’s permission, we modified all the remaining benches. It was a great outcome for Bucyrus and its associates.”