Quality improvement through ergonomics intervention at chemical plant

Abstract

Purpose This paper aims to focus on ergonomics intervention and quality implementation at a chemical manufacturing plant in Saudi Arabia that is prone to increased number of quality defects and shutdowns. Design/methodology/approach The paper applies the quality improvement through ergonomics (QUITE) methodology as a solution to improve the level of plants quality and reliability. The QUITE implementation relies on a great amount of human participation and constant check of quality results. The study is conducted to solve two main problems in the plant under study, namely, degradation in the products quality and unsolved frequent shutdowns in the production line Findings The study findings suggested to automate the inspection process through “User Alert” system to stimulate the operator attention who triggers a corrective action to avoid any possible process upset of plant shutdown. The implementation increased productivity from 280 to 310 ton; quality conformance from 91.7 to 96.80 per cent; and reduced shutdown from 1.26 days to almost zero downtime. Originality/value The work shed the light on the effect of ergonomics on the quality of finished products. Usually, ergonomics is related to the work environment. However, ergonomics initiatives can spearhead improvement in production quality.