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Spirit AeroSystems Case Study: Best Practices for Planning and Deploying a Sustainable Ergonomics Process in Large Structure Aircraft Assembly

Sustaining an ergonomics process in a unique environment that commonly contains long cycle time operations and few classic workstations was a challenge that Spirit AeroSystems overcame.

This presentation highlighted their approach using the continuous improvement process Plan-Do-Check-Act (PDCA). By applying the principle of the PDCA cycle, the team was able to successfully launch the program and scale it across the massive facility.

The following topics were discussed:

• best practices for program development and execution
• strategies used to engage other key areas of an organization
• creative ways to find problems (or job tasks) that put a worker at a higher risk of developing a musculoskeletal disorder (MSD) injury and the strategies used to fix those areas. Examples will also be provided!
• the use of indicators to identify focus areas, such as lagging injury data, employee turnover, quality issues and physical limiters in employee selection (i.e., experienced, height/reach capabilities)

At the conclusion of this session, attendees were inspired to make creative workplace improvements at their organization.

Attendees learned:

• the necessary elements for managing ergonomics in a long cycle time operation (8-hours to 3-week)
• best practices and examples of how Spirit AeroSystems improved the workplace by developing effective solutions, even when there are few succinct workstations (often the product is the workstation)
• how a sustainable ergonomics program was managed across the Wichita, Kansas campus
• how Spirit AeroSystems engaged and supported personnel, including Industrial Engineers, Operations and the Lean teams

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