An Integrated Framework for Ergonomic Performance Assessment in Food Manufacturing: A Case Study Using Ergo-VSM, AHP, and TLS
Main Article Content
Keywords
lean manufacturing, ergonomics performance assessment, manufacturing ergonomic score, Ergo-VSM, analytical hierarchy process
Abstract
In food processing industries, particularly nut-based production that relies heavily on manual labor, ergonomic challenges related to repetitive motion, prolonged static postures, and thermal stress are increasingly prominent due to rising production demands. These issues are often concentrated at specific workstations and tend to be overlooked in conventional performance evaluations. To address this gap, this study proposes an integrated Ergonomic Performance Assessment (EPA) framework designed to evaluate ergonomic performance comprehensively across the entire production line. The framework integrates Ergonomic Value Stream Mapping (Ergo-VSM) for process visualization, the Analytical Hierarchy Process (AHP) for assigning weights to ergonomic criteria, and the Traffic Light System (TLS) for intuitive performance classification. A case study was conducted in a peanut processing facility, involving 8 workstations. Data were gathered through direct observations, detailed task analyses, and expert input from three experts via Focus Group Discussions (FGDs). Ergonomic indicators were derived from literature and expert consensus, weighted using AHP based on pairwise comparisons, and assessed using structured observational metrics. The results were visualized within the Ergo-VSM framework using TLS. Ergonomic performance was quantified through the Manufacturing Ergonomic Score (MES), which reached 69.15%. Based on a three-tier classification system low (<60%), moderate (60–90%), and high (>90%) this score falls within the moderate category, indicating several areas require improvement. Musculoskeletal disorder risks and high working temperatures were identified as the most critical concerns, particularly at thermally intensive and physically demanding workstations. The EPA framework enabled the visualization of ergonomic variation between workstations, allowing for systematic identification of priority areas for improvement. This research contributes to ergonomic evaluation literature by offering a structured, data-driven approach and provides practical insights for enhancing worker well-being and operational productivity.
References
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[43] S. Sajiyo et al., "Analysis of Work Fatigue in Preventing Work Accidents: A Case Study of Human Comfort Pulse Rate in Wood Processing Industry Workers," International Journal Of Scientific Advances, 2024.
[44] S. R. K. Harish, M. Vamshi, B. Prakash, P. Ezra, F. Emmatty, and V. Panicker, "Identification of Factors Influencing Mental Workload in Manual Sorting," pp. 671-678, 2020.
[45] R. Anaya-Aguilar, M. Suárez-Cebador, J. Rubio-Romero, and F. Galindo-Reyes, "Delphi assessment of occupational hazards in the wineries of Andalusia, in southern Spain," Journal of Cleaner Production, 2018-09-01 2018.
[46] F. T. Lahudin, R. Rachmaniyah, K. Khambali, R. Rusmiati, S. Sutanto, and A. Ahmad, "Effect of Work Climate on Labor Fatigue in Kediri Tofu Factory in 2021," International Journal of Advanced Health Science and Technology, 2022-10-27 2022.
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[2] G. Zhenjing, S. Chupradit, Y. Kuo, A. A. Nassani, and M. Haffar, "Impact of Employees' Workplace Environment on Employees' Performance: A Multi-Mediation Model," Frontiers in Public Health, vol. 10, 05/13 2022.
[3] E. Faez, S. A. Zakerian, K. Azam, K. Hancock, and J. Rosecrance, "An Assessment of Ergonomics Climate and Its Association with Self-Reported Pain, Organizational Performance and Employee Well-Being," International Journal of Environmental Research and Public Health, vol. 18, no. 5. doi: 10.3390/ijerph18052610
[4] K. Bhui, S. Dinos, M. Galant-Miecznikowska, B. de Jongh, and S. Stansfeld, "Perceptions of work stress causes and effective interventions in employees working in public, private and non-governmental organisations: A qualitative study," BJPsych Bulletin, vol. 40, pp. 318-325, 12/01 2016.
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[6] A. F. Fernandes, T. F. L. Machado, J. R. D. Mafra, M. C. R. Vidal, and L. Moreira, "ECONOMICS OF ERGONOMICS: ERGONOMIC ACTION APPLIED IN THE PACKAGING SECTOR OF FOOD COMPANY IN RIO DE JANEIRO," Revista Ação Ergonômica, 2020.
[7] D. Hofmann, M. Burke, and D. Zohar, "100 Years of Occupational Safety Research: From Basic Protections and Work Analysis to a Multilevel View of Workplace Safety and Risk," Journal of Applied Psychology, vol. 102, 01/26 2017.
[8] R. Koirala and A. Nepal, "Literature Review on Ergonomics, Ergonomics Practices, and Employee Performance," Quest Journal of Management and Social Sciences, vol. 4, pp. 273-288, 12/21 2022.
[9] O. Erdinc and Ö. Vayvay, "Ergonomics interventions improve quality in manufacturing: A case study," International Journal of Industrial and Systems Engineering, vol. 3, 01/01 2008.
[10] K. S. Tee et al., "A study on the ergonomic assessment in the workplace," AIP Conference Proceedings, vol. 1883, no. 1, p. 020034, 2017.
[11] H. B. Mohd Fazi, N. M. Z. B Nik Mohamed, and A. Q. Bin Basri, "Risks assessment at automotive manufacturing company and ergonomic working condition," IOP Conference Series: Materials Science and Engineering, vol. 469, no. 1, p. 012106, 2019/01/01 2019.
[12] A. Arce, L. F. Romero-Dessens, and J. A. Leon-Duarte, "Ergonomic Value Stream Mapping: A Novel Approach to Reduce Subjective Mental Workload," in Advances in Social & Occupational Ergonomics, Cham, 2018, pp. 307-317: Springer International Publishing.
[13] A. Colim et al., "Towards an Ergonomic Assessment Framework for Industrial Assembly Workstations—A Case Study," Applied Sciences, vol. 10, no. 9. doi: 10.3390/app10093048
[14] S. Kundgol, P. Petkar, and V. N. Gaitonde, "Implementation of value stream mapping (VSM) upgrading process and productivity in aerospace manufacturing industry," Materials Today: Proceedings, vol. 46, pp. 4640-4646, 2021/01/01/ 2021.
[15] A. N. M. Rose, N. M. Z. N. Mohamed, M. F. F. Ab Rashid, H. M. Noor, and A. Mohd, "Improving productivity through value stream mapping (VSM): A case study at electrical & electronic company," Journal of Physics: Conference Series, vol. 1532, no. 1, p. 012005, 2020/06/01 2020.
[16] Y. Qin and H. Liu, "Application of Value Stream Mapping in E-Commerce: A Case Study on an Amazon Retailer," Sustainability, vol. 14, no. 2. doi: 10.3390/su14020713
[17] L. Ben Fredj-Ben Alaya, "VSM a powerful diagnostic and planning tool for a successful Lean implementation: a Tunisian case study of an auto parts manufacturing firm*," Production Planning & Control, vol. 27, no. 7-8, pp. 563-578, 2016/06/10 2016.
[18] C. Jarebrant, J. Winkel, J. Hanse, S. Mathiassen, and B. Öjmertz, "ErgoVSM: A Tool for Integrating Value Stream Mapping and Ergonomics in Manufacturing," Human Factors and Ergonomics in Manufacturing & Service Industries, vol. 26, 03/01 2015.
[19] T. Sakthi Nagaraj, R. Jeyapaul, K. E. K. Vimal, and K. Mathiyazhagan, "Integration of human factors and ergonomics into lean implementation: ergonomic-value stream map approach in the textile industry," Production Planning & Control, vol. 30, no. 15, pp. 1265-1282, 2019/11/18 2019.
[20] D. Dominguez-Alfaro, I. Mendoza-Muñoz, C. R. Navarro-González, M. I. Montoya-Reyes, S. E. Cruz-Sotelo, and O. Y. Vargas-Bernal, "ErgoVSM: A new tool that integrates ergonomics and productivity," Journal of Industrial Engineering and Management; Vol 14, No 3 (2021)DO - 10.3926/jiem.3507, 07/19/ 2021.
[21] K. Edwards and J. Winkel, Ergonomic Value stream Mapping (ErgoVSM) – potential for integrating work environment issues in a Lean rationalization process at a Danish hospital. 2013.
[22] T. Sakthi Nagaraj, J. Rajamani, V. K. E. K., and K. and Mathiyazhagan, "Integration of human factors and ergonomics into lean implementation: ergonomic-value stream map approach in the textile industry," Production Planning & Control, vol. 30, no. 15, pp. 1265-1282, 2019/11/18 2019.
[23] S. Afroz and M. I. Haque, "Ergonomics in the Workplace for a Better Quality of Work Life," in Ergonomics for Improved Productivity, Singapore, 2021, pp. 503-511: Springer Singapore.
[24] T. Y. Rosiani, D. M. Utama, A. Y. Ummudiyah, and I. Amallynda, "Sustainable Manufacturing Assessment using Sustainable VSM and AHP involving Workload and Machine Efficiency: A Case Study in Indonesian Paving Block Production," Circular Economy and Sustainability, 2024/04/16 2024.
[25] D. Domínguez-Alfaro, I. Mendoza-Muñoz, M. I. Montoya-Reyes, O. Y. Vargas-Bernal, and G. Jacobo-Galicia, "Design and Implementation of Integral Ergo-Value Stream Mapping in a Metal-Mechanical Company to Improve Ergonomic and Productive Conditions: A Case Study," Logistics, vol. 7, no. 4. doi: 10.3390/logistics7040100
[26] G. K. Abinaya Ishwarya and D. Rajkumar, "Analysis of ergonomic risk factors in construction industry," Materials Today: Proceedings, vol. 37, pp. 2415-2418, 2021/01/01/ 2021.
[27] S. Mathiassen, J. C, Ö. B, and J. Winkel, Ergonomic Value Stream Mapping – an integrated rationalization tool considering ergonomics and productivity. 2004.
[28] K. Edwards et al., Evaluation and development of an ergonomic complement to the Value Stream Mapping tool – a NOVO multicenter Study plan. 2009.
[29] A. Otto and O. Battaïa, "Reducing physical ergonomic risks at assembly lines by line balancing and job rotation: A survey," Computers & Industrial Engineering, vol. 111, pp. 467-480, 2017/09/01/ 2017.
[30] I.-J. Kim, "Cognitive Ergonomics and Its Role for Industry Safety Enhancements," Journal of Ergonomics, vol. 6, 01/01 2016.
[31] S. Hartini, U. Ciptomulyono, M. Anityasari, and Sriyanto, "Manufacturing sustainability assessment using a lean manufacturing tool," International Journal of Lean Six Sigma, vol. 11, no. 5, pp. 943-971, 2020.
[32] W. Faulkner and F. Badurdeen, "Sustainable Value Stream Mapping (Sus-VSM): methodology to visualize and assess manufacturing sustainability performance," Journal of Cleaner Production, vol. 85, pp. 8-18, 2014/12/15/ 2014.
[33] S. G. Hart and L. E. Staveland, "Development of NASA-TLX (Task Load Index): Results of Empirical and Theoretical Research," in Advances in Psychology, vol. 52, P. A. Hancock and N. Meshkati, Eds.: North-Holland, 1988, pp. 139-183.
[34] V. Arumugaprabu, S. Ajith, J. Jerendran, K. Naresh, and P. S. Rama Sreekanth, "Hazard identification and risk assessment using integrated exposure frequency and legislation requirements (HIRA-FL) in construction sites," Materials Today: Proceedings, vol. 56, pp. 1247-1250, 2022/01/01/ 2022.
[35] D. M. Utama, N. Ardiyanti, and A. A. Putri, "A new hybrid method for manufacturing sustainability performance assessment: a case study in furniture industry," Production & Manufacturing Research, vol. 10, no. 1, pp. 760-783, 2022/12/31 2022.
[36] H. RISK, "Hazard Identification and Risk Assessment," 1996.
[37] N. Kosim and A. Rahman, "Pengukuran Kinerja Menggunakan Metode BSC Dan Pembobotan AHP Di PT Suzuki TSM," Jurnal Optimasi Teknik Industri (JOTI), vol. 4, no. 1, pp. 1-6, 2022.
[38] A. Mubin, D. M. Utama, and R. C. Nusantara, "Manufacturing Sustainability Assessment Comprising Physical and Mental Workload: An Integrated Modified SVSM and AHP Approach," Process Integration and Optimization for Sustainability, vol. 7, no. 1, pp. 407-417, 2023/03/01 2023.
[39] T. Saaty, The Analytic Hierarchy Process. 1996.
[40] K. Kataria, M. Sharma, S. Kant, N. Suri, and S. Luthra, "Analyzing musculoskeletal risk prevalence among workers in developing countries: an analysis of small-scale cast-iron foundries in India," Archives of Environmental & Occupational Health, vol. 77, pp. 486-503, 2021-06-15 2021.
[41] A. Nugraha and N. Widajati, "Ergonomic risks in manual material handling activities and musculoskeletal disorders complaints in the animal feed industry production area in East Java, Indonesia," World Journal of Advanced Research and Reviews, 2024-04-30 2024.
[42] A. Pratiwi, "The Correlation between Physical Environmental Factors and Fatigue of The Workers at Ship Repair Workshop," The Indonesian Journal of Occupational Safety and Health, 2019-12-27 2019.
[43] S. Sajiyo et al., "Analysis of Work Fatigue in Preventing Work Accidents: A Case Study of Human Comfort Pulse Rate in Wood Processing Industry Workers," International Journal Of Scientific Advances, 2024.
[44] S. R. K. Harish, M. Vamshi, B. Prakash, P. Ezra, F. Emmatty, and V. Panicker, "Identification of Factors Influencing Mental Workload in Manual Sorting," pp. 671-678, 2020.
[45] R. Anaya-Aguilar, M. Suárez-Cebador, J. Rubio-Romero, and F. Galindo-Reyes, "Delphi assessment of occupational hazards in the wineries of Andalusia, in southern Spain," Journal of Cleaner Production, 2018-09-01 2018.
[46] F. T. Lahudin, R. Rachmaniyah, K. Khambali, R. Rusmiati, S. Sutanto, and A. Ahmad, "Effect of Work Climate on Labor Fatigue in Kediri Tofu Factory in 2021," International Journal of Advanced Health Science and Technology, 2022-10-27 2022.
[47] H. Mujib et al., "Working Climate with Fatigue Levels of Timber Industry Workers in Probolinggo," Indian Journal of Physiotherapy and Occupational Therapy—An International Journal, vol. 12, pp. 225-229, 2018-11-05 2018.
[48] K. Hemati et al., "Ergonomic intervention to reduce musculoskeletal disorders among flour factory workers," Work, 2020-09-21 2020.
[49] F. Herkrath, L. M. Beiga, E. G. Menezes, M. A. S. Júnior, K. A. Scantbelruy, and J. Estrázulas, "ERGONOMIC INTERVENTIONS IN INDUSTRIES IN THE ELECTRO-ELECTRONIC SECTOR: A SYSTEMATIC REVIEW OF THE LITERATURE," Revista Ação Ergonômica, 2022.
[50] W. Susihono, Ariesca, Suryanawati, Mirajiani, and G. Gunawan, "Design of standard operating procedure (SOP) based at ergonomic working attitude through musculoskeletal disorders (Msd’s) complaints," vol. 218, p. 4019, 2018.
[51] A. S. Moreira and S. R. De Lucca, "Physical and mental fatigue in shift work and mitigation strategies: an integrative review," Revista Brasileira de Medicina do Trabalho, vol. 22, 2025-01-13 2025.
[52] D. P. Restuputri et al., "Musculoskeletal Disorders Analysis Of Indonesian Women Farmers With Quick Exposure Check Method," Jurnal Perempuan dan Anak, vol. 4, no. 1, pp. 25-35, 2021.
[53] C. Kurnia and A. Widigdo, "Effect of Work-Life Balance, Job Demand, Job Insecurity on Employee Performance at PT Jaya Lautan Global with Employee Well-Being as a Mediation Variable," European Journal of Business and Management Research, 2021-09-24 2021.
[54] A. Hilmi, A. R. A. Hamid, and W. A. R. A. W. Ibrahim, "Human-Centered Ergonomics: Advancements, Challenges, and Future Directions in Industrial and Occupational Settings," Malaysian Journal of Ergonomics (MJEr), 2024-12-31 2024.
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Jun 30, 2025
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T. Y. Rosiani, M.-H. Li, and D. Rahmasari, “An Integrated Framework for Ergonomic Performance Assessment in Food Manufacturing: A Case Study Using Ergo-VSM, AHP, and TLS”, J. Optimasi Sist. Ind., vol. 24, no. 1, pp. 84–101, Jun. 2025.
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