International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 04 Issue: 10 | Oct -2017 www.irjet.net p-ISSN: 2395-0072 © 2017, IRJET | Impact Factor value: 6.171 | ISO 9001:2008 Certified Journal | Page 1985 ERGONOMICS IMPROVEMENTS IN A PAINT MANUFACTURING COMPANY Okpala 1 , Charles Chikwendu 2 , Ihueze 3 , Christopher Chukwutoo 4 1,2,3,4 Department of Industrial/Production  Nnamdi Azikiwe University, Awka, Anambra State, Nigeria. -------------------------------------------------------------------***--------------------------------------------------------------- Abstract: The work environment has a potential of adversely affecting staff’s performance in diverse ways ranging from displeasure, fatigue, frustration, and minor or major injuries that decrease the workers’ ability to accomplish the daily tasks, and even deaths in extreme cases. Also known as human factors engineering, the goal of ergonomics is to fit the job to the worker, not the worker to the job. This paper examined the role of ergonomics in manufacturing, and the results of its application in a paint manufacturing company. The frequent cases of Work- related Musculoskeletal Disorders (WMSD) were tackled by the installation of sit-standing variety of chairs and new ergonomic chairs with many adjustable functions to enhance convenience. To achieve illumination of up to 1000 lux in order to easily see and address quality issues, more fluorescent light tubes were installed to attain uniform illumination level, while 1.438 were calculated as the average total noise the machines subject the operators for 8 hours of use each day. This was resolved by the installation of sound insulating covers for many processes to improve oral communication. Also, the ambient noise level at the workstations was decreased from around 78 to 62 dBA, thereby enabling the workers to discuss freely without undue interference. The application also achieved 21%, 22%, and 24% improvements in throughput, workers’ productivity, and injury reduction respectively, and 62,300 dollars total cost reduction in six months. However, the firm was unable to record appreciable waste detection and possible elimination during the period under review, hence the introduction of Five-S housekeeping practice was advocated. Keywords: manufacturing; ergonomics; musculoskeletal disorders; safety; shop floor; work station; operators; productivity; throughput; human factors engineering 1. INTRODUCTION Fatigued, sick and frustrated workforce are some of the consequences of poorly designed plant layout and work station which leads to decrease in productivity, income and efficiency, low product quality, increased medical claims, musculoskeletal disorders, as well as disabilities. Hence, the need for ergonomics in the manufacturing industries. Wolfgang and Joachim (2017), explained that ergonomics Dzexamines not only the passive ambient situation but also the unique advantages of the human operator and the contributions that can be made if a work situation is designed to permit and encourage the person to make the best use of his or her abilities.dz As the science of studying people’s efficiency in the work environment and the modalities and processes to be added to enhance their health and productivity all through the working hours, ergonomics entails proper designing of a job to fit a worker in order to ensure more efficient and safety work. Also known as human factors engineering, ergonomics is defined by Middlesworth ȋʹͲͳ͸Ȍ, as Dzthe scientific discipline concerned with the understanding of interactions among humans and other elements of a system, and the profession that applies theory, principles, data and methods to design, in order to optimize human well-being and overall system performance.dz )t encompasses other scientific disciplines like psychology, mechanical/industrial engineering, industrial and information designs, kinesiology, industrial safety, biomechanics, as well as anthropometry, and instead of physically compelling the worker to fit the job, it fits the job to the worker. To optimize man-machine integration in order to enhance precision and rate of work is the main objective of ergonomics. It involves the design of a favourable workstation, the increasing of efficiency by reducing mental and physical strain of workers. The objective is aimed at optimizing the integration of man and machine, so as to improve the work rate and accuracy, as well as the organization of daily tasks at work. Other objectives are the improvement of machines and equipment at the early or design stage of production, profit enhancement and cost reduction by reduction or possible elimination of accidents, fatigues, mistakes and death without tampering with the product quality.