Bobcat Ergonomic Process Improvement
Problem statement
In Bobcat’s current manufacturing process, operators in the paint line manually lift and handle parts weighing around 50 lbs multiple times per shift. This repetitive heavy lifting places a significant physical strain on workers, increasing the risk of musculoskeletal disorders, as shown in the Occupational Safety and Health Administration (OSHA) [1]. In addition, operators working the pound press perform repetitive hammering tasks to remove parts from metal sheets, which also pose ergonomic risks. While the pound press issue is important, the severity of manual lifting in the paint line is a bigger concern, making it the primary focus of our project. If nothing is done about it, these ergonomic issues can lead to higher injury rates and decreased overall productivity [2]. Bobcat is already working on solutions to alleviate the strain on operators by cutting larger sheets into smaller, rectangular sheets for easier handling. Several tools, such as magnetic handles and hoists, are also available to aid in lifting tasks. In our senior design project, we will collaborate with these existing methods and implement additional measures to make the process more ergonomic. Our project aims to mitigate these risks by researching and proposing solutions to reduce or eliminate manual lifting, while also supporting optimization of the pound press process. We will conduct multiple on-site assessments (if needed), develop ergonomic reports, and propose designs using SolidWorks. While the upfront costs of implementing these changes may pose a challenge, the long-term benefits of a safer, more efficient process—reduced injury rates, increased productivity, and improved operator morale—make a compelling case for action. [1] Occupational Safety and Health Administration, “Ergonomics: The Study of Work,” OSHA, 2023. [Online]. Available: https://www.osha.gov/ergonomics. [2] U.S. Bureau of Labor Statistics, “Nonfatal Occupational Injuries and Illnesses Requiring Days Away From Work,” BLS, 2023. [Online]. Available: https://www.bls.gov/news.release/osh2.nr0.htm.
Team members 
Ari Wainer – facilitator
Tejas Chhajer – communicator
Cole Pendleton – accountant
Giancarlo Rodriguez – admin
Client
Doosan Bobcat