Design and Implementation of Integral Ergo-Value Stream Mapping in a Metal-Mechanical Company to Improve Ergonomic and Productive Conditions: A Case Study

Abstract

The Integral Ergonomic-Value Stream Mapping (Ergo-VSM) methodology is introduced in this study, which is tailored for the metal-mechanic sector and aims to assess the operational and ergonomic conditions of production processes. The methodology is designed to identify ergonomic risks and propose an improvement plan to increase productivity by integrating ergonomic measurement instruments aligned with official standards and lean manufacturing tools such as VSM and Kaizen. The study, which was conducted in a metal-mechanical MSME (micro, small and medium enterprises), resulted in an 11.8% overall improvement in psychosocial risk factors, a 4.4% increase in productivity with a 1.96-h reduction in cycle time, and a 20% decrease in reported quality rejections. Notably, the study shows that the Integral Ergo-VSM can be implemented in a variety of organizational contexts, ensuring adaptability without jeopardizing the methodology’s core objectives.