Traditional ergonomic risks remain widespread across various sectors, with 40% to 75% of workers reporting exposure to these hazards. This underscores the ongoing need for effective ergonomic interventions.
Musculoskeletal disorders, however, are particularly challenging to identify as occupational diseases. Their delayed onset and the need for extended observation to detect ergonomic risks make diagnosis more complex.
The automotive industry faces similar challenges, and AKA Otomotiv has taken a real step to address them. Moving beyond manual REBA & RULA assessments, they turned to AI and implemented Intenseye's Ergonomics AI solution to tackle ergonomic risks more effectively.
AI-powered REBA & RULA assessment
Intenseye’s Ergonomics AI software addresses this current challenge by continuously assessing working bodies and translating ergonomic risks into measurable REBA and RULA scores. This approach simplifies the identification of repetitive motions, requiring action and allowing for validation of corrective measures through measurable improvements in REBA & RULA scores.
AKA Automotive is dedicated to reducing musculoskeletal disorder cases
AKA Automotive, an enterprise in the automotive industry, observed a rise in musculoskeletal disorder cases reported to their occupational physician. In response, the company decided to invest in AI-powered ergonomics solutions.
By adopting Intenseye's ergonomics module, AKA Automotive gained the ability to analyze the body mechanics of multiple frontline employees simultaneously in shared workspaces, enabling the identification of workers at risk in real time.
Taken corrective actions for better ergonomics performance
Shifting from manual RULA and REBA assessments to AI-generated analyses paved the way for a more data-driven and comprehensive ergonomic risk evaluation process.
With insights from Intenseye's AI-powered analyses, the company more accurately identified elevated RULA and REBA scores and took corrective actions to enhance their ergonomic performance:
• Implemented a hoist system to reduce ergonomic risks associated with repetitive lifting tasks.
• Redesigned the chair and table setups in the assembly department.
• Adjusted workbench heights in welding stations.
• Provided back support belts to personnel for mechanical handling of axles and lifting large-surface materials.
• Delivered 708 man-hours of additional training on ergonomic working techniques to employees.
As a result of these corrective measures, the number of cases reporting musculoskeletal disorders to the occupational physician decreased significantly, from 362 cases in 2023 to 102 cases in 2024 (January–September), marking a 71.82% reduction.
The occupational physician of AKA Automotive, Hakan Aydınlık shares this thoughts on Intenseye and points out the need for transforming how the industry approaches ergonomics:
“Protecting the health of workers in physically demanding jobs and enhancing workforce productivity is of great importance. Repeated movements or poor posture, in particular, can cause cumulative stress on the musculoskeletal system, leading to serious health issues. Therefore, implementing ergonomics training and observing working conditions on-site offer a proactive approach to health by reducing potential risks.
Proper ergonomics practices can prevent problems like herniated discs, nerve compressions, and muscle tears while reducing workplace accidents and labor loss. Practical training and site assessments help translate theoretical knowledge into practice, directly benefiting workers.
In this regard, Intenseye’s Ergonomics program we've implemented at AKA Automotive has been highly important in identifying ergonomic risks in our operations and addressing them effectively.
Additionally, as a digital AI system, it allows for assessments across multiple areas and enables targeted actions, saving significant time and labor resources.”
Having taken the corrective actions, AKA Automotive's EHS teams now track their performance through periodic health screenings, which revealed better working conditions and enhanced employee satisfaction.
