Development of framework integrating ergonomics in Lean’s Muda, Muri, and Mura concepts

Abstract

Lean and ergonomics are two disciplines that shared common goals to improve manufacturing production systems. However, there are limited studies that specifically link ergonomics with Lean’s 3 M concept of Muda (waste), Muri (overburden), and Mura (inconsistency). The study employed semi-structured interview with 10 experienced practitioners on past lean projects to establish potential linkage between ergonomics and Lean’s 3 M. A conceptual framework integrating ergonomics components into the Lean’s 3 M components was then generated through group discussion, and validated using Fuzzy Delphi Method analysis. The interviews revealed four themes linking ergonomics to Lean’s 3 M: (1) Human energy waste, (2) Uneven workload distribution, (3) Overburden of worker’s capacity, and (4) Worker performance affects work performance. A conceptual framework integrating ergonomics components into the Lean’s 3 M components was then proposed, which redefines several components of Lean’s 3 M from ergonomics perspective. Fuzzy Delphi Method analysis on 12 practitioners showed overall agreement with the content, structure, and applicability of the proposed framework (threshold (d) value ≤0.2, expert consensus ≥75%, and fuzzy score ≥0.5). The findings may provide platform for lean and ergonomics practitioners to communicate and bridge the gaps between the two disciplines.