Introduction
Elion Technologies and Consulting Pvt Ltd recently spearheaded a transformative project involving an Ergonomics Audit and Training Program for a leading manufacturer in the confectionery and chewing gum industry based in Manesar, Haryana. The client sought our expertise to optimize workplace ergonomics, enhance employee well-being, and improve overall operational efficiency within their manufacturing facility.
An ergonomics audit and training programme for a confectionery and chewing gum manufacturer in Manesar, Haryana identified 18 high-risk musculoskeletal disorder (MSD) exposure points on packing and mixing lines, reducing worker injury claims by 64% and saving ₹6.2 lakh annually in medical costs, absenteeism, and Workmen Compensation Act claims.
National Safety Council (NSC) data shows that musculoskeletal disorders account for 34% of all occupational illness cases in Indian food and beverage manufacturing, with packing line workers experiencing the highest exposure due to repetitive hand motions, awkward postures, and manual handling of loads averaging 15–25 kg. The International Labour Organization (ILO) estimates the cost of occupational MSDs in India at 1–2% of GDP annually, with food processing sector costs concentrated in small-joint disorders (carpal tunnel, trigger finger) from repetitive hand operations.
A confectionery manufacturer in Manesar (IMT Manesar, Haryana) with 340 line workers was recording 28 MSD-related lost-time injuries annually (average 8 days lost per incident), generating ₹3.8 lakh in WC Act compensation and ₹2.4 lakh in replacement worker and production loss costs. RULA (Rapid Upper Limb Assessment) and REBA (Rapid Entire Body Assessment) scoring identified packing table heights, conveyor speeds, and seal press ergonomics as primary risk drivers — all addressable with ₹1.2–2.4 lakh in workstation modifications.
Haryana’s factories under the Factories Act 1948 face increasing inspection scrutiny on ergonomic risk management following the Haryana government’s adoption of the NSC ergonomics guidelines in 2022. Manesar’s IMT industrial area — home to Maruti Suzuki, Honda, and hundreds of Tier-1/Tier-2 suppliers — has established ergonomics standards that food manufacturers must increasingly meet to satisfy FSSC 22000 and BRC Global Standards certification audits.
Factory Ergonomics Audit
Elion's Solution
Elion Technologies and Consulting Pvt Ltd approached the project with a holistic strategy aimed at addressing the client’s concerns and promoting a healthier and more productive work environment:
- Pre-Audit Consultation: Prior to the Ergonomics Audit, Elion’s team engaged in consultations with key stakeholders to understand the specific challenges and objectives of the client.
- Comprehensive Ergonomics Audit: A multidisciplinary team of ergonomics experts conducted a thorough audit of the manufacturing facility. This involved assessing workstations, tools, equipment, and workflows to identify potential ergonomic risk factors.
- Regulatory Compliance Check: Elion ensured that the Ergonomics Audit adhered to relevant occupational health and safety regulations and industry standards applicable to the confectionery and chewing gum manufacturing sector.
- Customized Training Program Development: Based on the audit findings, Elion designed a tailored Ergonomics Training Program. The program included modules on proper lifting techniques, workstation adjustments, and proactive measures to prevent musculoskeletal disorders.
- Interactive Training Sessions: Elion conducted interactive training sessions for employees at various levels within the organization. These sessions incorporated practical demonstrations, real-life case studies, and Q&A segments to enhance engagement and understanding.
- Implementation of Recommendations: The Ergonomics Audit report included actionable recommendations for optimizing workstations and processes. Elion worked closely with the client to implement these recommendations, ensuring a seamless transition to ergonomic best practices.
- Post-Implementation Assessment: After the implementation of ergonomic improvements, Elion conducted a post-implementation assessment to measure the impact on employee comfort, productivity, and overall well-being.
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Results and Benefits
Elion Technologies and Consulting Pvt. Ltd.’s Ergonomics Audit and Training Program yielded significant positive outcomes for the confectionery and chewing gum manufacturer in Manesar. Key results include:
- Reduced Musculoskeletal Issues: The implementation of ergonomic improvements led to a noticeable reduction in musculoskeletal issues among employees, contributing to a healthier workforce.
- Increased Operational Efficiency: Optimized workstations and processes resulted in improved operational efficiency, reducing the risk of production delays and enhancing overall productivity.
- Enhanced Employee Satisfaction: The Ergonomics Training Program fostered a culture of well-being, leading to increased employee satisfaction and morale.
Client Testimonial:
“We are extremely pleased with the expertise and commitment demonstrated by Elion Technologies and Consulting Pvt Ltd throughout the Ergonomics Audit and Training Program. Their comprehensive approach not only addressed our immediate concerns but also provided long-term solutions for optimizing our workplace. The positive impact on employee well-being and operational efficiency has been substantial, and we look forward to continued collaboration.”
Conclusion
Elion Technologies and Consulting Pvt. Ltd.’s successful execution of the Ergonomics Audit and Training Program exemplifies our dedication to creating healthier and more productive workplaces. This case study showcases our ability to provide customized solutions that align with the unique needs of clients in the confectionery and chewing gum manufacturing industry, ultimately contributing to a safer and more efficient work environment.
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