Survey and Research Data 

Lean Manufacturing and decreased worker stress 

Templeton College at the University of Oxford carried out a 3 year investigation concerning lean manufacturing. The study, involving 1391 factory workers in the UK, revealed that lean production systems can actually improve some of the more stressful elements associated with working in a production line environment. Effectively implemented lean systems were reported as being able to deliver high quality and productivity without undue strain on the work force. Lean factories are designed to be efficient, with carefully designed work spaces, effective and easily accessed tools, and an engaged work force, all of which significantly reduce worker stress. The study, which looked at production across a range of industries, showed that inappropriate tools, poor ergonomic design, lack of control over working hours, and blame for defects are factors that workers find stressful. [10]

The following data reports on an Association for Manufacturing Excellence survey of US manufacturers which related to the implementation of Lean Engineering systems:

• 41% said they did not really know what lean was;

• 34% were familiar with lean but were not sure how to go about achieving it;

• 22% indicated that they were on the lean path, but were not getting the results expected;

• 3% indicated that they were achieving great results.

In addition to productivity gains the 3% of firms with successful lean transformations reported:

• A reduction in lead times of 95%,

• A reduction in accident rates of 95%,

• A reduction in customer complaint/reject rates of 95%, and

• A reduction in floor space of more than 80%. [11]

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