Enhancing manufacturing performance and working conditions: AgErgoVSM – Innovative integration of lean and ergonomics for an ageing workforce

The sociodemographic challenge, more precisely the ageing workforce, brings several consequences for industrial systems, particularly in terms of productivity and work performance. The age-productivity relationship has different effects on productivity and system performance, since industrial productivity tends to decrease with ageing, but becomes more balanced when operators gather experience and know-how. In addition, ageing operators tend to show a reduction in their physical capacity, which is why it is necessary to adopt strategies for prolonging their active, safe, and healthy life. So, this study introduces a case study on the application of a novel integrative Lean tool, AgErgoVSM, which incorporates ergonomic considerations for different age demographics within the metalworking industry, with a focus on manual polishing tasks. To address the challenges and opportunities posed by workforce age diversity, with a specific emphasis on workers from different age clusters, the methodology involved a systematic approach that began with mapping the current state of work tasks, including assessments of physical ergonomics, mental demands, and control/influence at work. The findings revealed varied implications for workers of different ages, such as high physical demands for older workers and high mental demands for younger workers, along with limited communication at work. Thus, this research underscores the need for tailored physical and cognitive ergonomic interventions to enhance working conditions across different age clusters. It emphasises the importance of integrating ergonomic principles into the workplace environment to boost productivity while ensuring the health and well-being of operators in more efficient work environments that accommodate the diverse needs of the workforce. • Ageing workforce challenges impact productivity and performance in industry. • Experience can offset age-related decline, but physical capacity still drops. • Study applied AgErgoVSM tool in metalwork, focusing on manual polishing. • Results show age-based needs: older workers face more physical strain. • Future work must adapt tasks ergonomically for all age demographics.