A recent experiment at a BMW car plant in Germany suggests an ageing workforce is not necessarily a problem. The BMW powertrain plant in Dingolfing, southern Bavaria, faced an increase in worker age from 39 in 2007 to 47 in 2017, risking a productivity decline. Two department managers and the workers’ council came up with a combination of ergonomics, work-time rules and health and nutrition education.
a test production line was set up staffed by workers with an average age of 47. The workers participated in workshops in their own (unpaid) time and came up with 70 load-easing changes: from a wooden floor that dampened pounding and allowed easier turning, to cushioned shoes, tilted screens with bigger lettering, height-adjustable workbenches, tools with lower gripping force, and leather chair cushions instead of plastic. A work rotation was introduced in the middle of the shift.
These changes were cheap to install and reduced fatigue. Logistics and maintenance personnel helped by making adjustments quickly within normal working hours and an ergonomist gave advice. After one year, the line was as productive as lines with people 10 years younger (while delivering perfect quality throughout), at a cost of €40,000. BMW has incorporated the practices in its production system.
According to Lock, it is a glimpse of what might be possible. Organisations can unlock innovation by helping people figure it out for themselves. Source: Sunday Times, 14 February, 2010. tinyurl.com/yeu5my4
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