Background: The survival of manufacturing in the western world also depends on the ability to increase productivity. To achieve this goal, it is necessary to recover the efficiency of all workers suffering from upper limb biomechanical overload disease. Ergonomic methods can be a valuable tool in solving this apparent conflict: operatives'productivity and health.
Methods: After carrying out an ergonomic education and training programme for all company employees and risk assessment for upper limb biomechanical overload through the OCRA checklist method, a programme of improvements on a production line was planned and tested, mainly based on international and European standards.
Results: Within approximately 2 years, thanks to changes in workplace layout and organization, a significant reduction of 22.7% in risk level was achieved and, at the same time, a 16% increase in productivity.
Discussion: An ergonomic approach based on global, interdisciplinary and participatory principles in the case considered showed that it is possible to match increased productivity with decreased risk. In this specific case application of ergonomic principles during product design was rather poor, which is typical of companies working for third party customers.