Manual material handling is one of the most physically demanding operations where workers are exposed to repetitive movements, awkward postures, contact stresses, and forceful exertions. The study presents a case of ergonomic intervention in a manufacturing plant towards reducing the physical strain for workers undertaking material handling in a worksystem. Digital human model in CATIA was used for biomechanical analysis and for redesign of material handling worksystem where higher levels of physical exertions are observed. The ergonomic solutions for the material handling worksystem are presented.

Keywords: The design solution shall help the Industrial Engineers of the plant towards its implementation, and therefore enable reduction in the physical stress encountered by the workers in the specific worksystem studied.