Ergonomic Assessment For Repetitive Assembly Stations

The purpose of this SOP is to establish a consistent, evidence‑based procedure for identifying ergonomic risk factors at repetitive assembly stations. By standardizing the assessment method (using RULA and NIOSH thresholds), we enable objective risk prioritization, reduce the incidence of cumulative trauma disorders, and meet due‑diligence requirements under WorkSafeBC regulations.

This SOP applies to all repetitive assembly stations within light manufacturing, electronics assembly, automotive part assembly, and similar high‑frequency, low‑load operations. It does not cover material handling tasks that involve lifting loads > 23 kg (NIOSH limit) or non‑repetitive maintenance work. All ergonomic assessments must be conducted by a trained ergonomics coordinator or safety officer who has completed certified RULA training.

• LOTOBefore adjusting or modifying any workstation component (heights, conveyors, fixtures), perform lockout/tagout of the line. Ensure zero energy state before contact.
• PPEWear safety glasses, cut‑resistant gloves (if handling sharp parts), and steel‑toe boots. Long hair must be tied back; loose clothing secured.
• CAUTIONDo not approach active robotic or pneumatic assembly cells without proper training and authorization. Maintain minimum clearance of 1 m from moving actuators during observation.
• POSTUREAssessors must maintain neutral postures themselves. Use a stool or adjustable observation platform to avoid personal strain during extended evaluation sessions.

• Ergonomic assessment template (RULA / NIOSH checklist) — supplied by Safety Department
• Goniometer (mechanical or digital, ±1° accuracy)
• Measuring tape (metric, 5 m)
• Stopwatch or timer (precision 0.1 s)
• Digital camera or smartphone (capable of 1080p video at 30 fps)
• Clipboard and pen, or tablet with data entry app
• RULA grand score chart (laminated for field use)
• WorkSafeBC Preventing Musculoskeletal Injury (MSI) guide reference