Ergonomics Program Development

When the senior ergonomics manager of this global automotive manufacturer joined the team in 2012, they set out to revamp the company's ergonomics program with a structured, incident-reduction focus. Initially, the team relied on a spreadsheet-based internal tool for risk assessments. While effective to a point, it struggled to keep pace with the fast-moving automotive industry. By 2018, they began evaluating new technologies - ranging from sensors to camera-based solutions - that could improve speed and accuracy. After piloting and reviewing options, the automotive manufacturer implemented TuMeke Ergonomics in 2019 as the best-fit solution for scalability and usability.

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TuMeke Implementation & Benefits

Since adopting TuMeke, the automotive manufacturer has realized measurable improvements across its ergonomics program:

• >50% reduction in assessment time. Accelerating risk identification and leaving more time to design solutions.
• Improved employee engagement. Workers respond to TuMeke's scoring system with "gamification," naturally adjusting postures for higher scores.
• Clearer communication of risks. TuMeke's visuals make it simple to explain ergonomic issues to leadership, supervisors, and frontline workers.
• Proactive safety strategy. Teams use TuMeke for high-risk station reviews, onboarding new hires, and post-injury investigations.

Injury Reduction & Safety Performance

The automotive manufacturer is consistently ranked among the safest companies in the automotive sector.

• 40% lower MSD injury rate vs industry average
• Top quartile global safety performance
• 50% faster assessments
• 200+ sites supported with scalable ergonomic tools

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Scaling AI & Ergonomics

Currently, TuMeke is deployed in North America, parts of Europe, and the Middle East, with expansion plans based on regional business needs. Notably, the automotive manufacturer adopted TuMeke before launching its broader AI initiatives. Today, company leadership strongly supports AI adoption across functions—from manufacturing to ergonomics—positioning TuMeke as a foundational part of its innovation strategy.

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Download and read the full case study here.

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