Ergonomics done right.®
January 24th, 2018

WABCO Eliminates High-Risk Jobs Worldwide with The Humantech System

Founded in 1869, WABCO is the leading supplier of technologies and services that improve the safety, efficiency, and connectivity of commercial vehicles. The company provides innovations for advanced driver assistance, braking, stability control, suspension, transmission automation, and aerodynamics for the world’s commercial truck, bus, trailer, car, and off-highway vehicle manufacturers.

WABCO is committed to preventing accidents, and working safely is a condition of employment for each of its 13,000 employees occupying 40 countries. The company first initiated an ergonomics process in 2006, consisting of in-person training programs by Humantech experts and paper-based assessments using Humantech’s tools and methods (Ergonomics Hit List®, BRIEF™ Survey, and BEST™ assessment).

In 2013, WABCO became one of the early subscribers of The Humantech System®, an online ergonomics training, assessment, and management solution. Under the baton of the Safety, Health, and Environmental Director Ingeborg Ensing, WABCO developed a sustainable world-class ergonomics process across the globe.  “One thing that differentiates The Humantech System from other software solutions is the e-learning,” says Ricardo Massola, safety, health, and environmental physical therapist and global health expert. “Our biggest challenge prior to implementing The Humantech System globally was training and getting everyone (leadership and operators) on board,” says Massola.

Massola conducted a monthly meeting at each plant to ensure employees were completing the training requirements, and identifying and fixing ergonomics issues. Since training modules in The Humantech System can be viewed anytime, anywhere, and repeated multiple times, a new team member could view them during the first week of employment, and again later as a refresher course. By the end of the first year with The Humantech System, ergonomics had become part of WABCO’s culture with 100 percent (10,000) of its operators trained and ready to make job improvements.

After team members completed the training, live workshops were held on the shop floor to fix problem jobs. Environmental health and safety team members, manufacturing and lean engineers, process engineers, lean promotion officers, maintenance personnel, team leaders, and representatives from leadership all attended. “Since we used Humantech’s tools in the past, it was easy to transition to The Humantech System—so easy that everyone began using it,” says Massola.

While assessing a job, workshop attendees enter the data into The Humantech System. When data entry for all body segments is complete, the application generates a color-coded image of the human body, indicating low-risk (green), medium-risk (yellow), and high-risk (red) on affected body segments. An overall risk score for the job is also calculated. “These dashboards act as our status report and are reviewed at our monthly leadership meeting. They allow us to see the issues we have today, and at each site, and proactively calculate where we want to be in the future,” says Massola.

The ability to filter the data by site, state, or country is especially helpful to the team. “The Humantech System helped our process mature both locally and globally. The data helps our sites establish local action plans to eliminate risk. On a global level, we can track the sites’ performance and establish global policies and goals based on our expected results.”

Today, WABCO has eliminated all high-risk jobs from its 32 facilities worldwide. Since implementation of The Humantech System, over 3,000 jobs have been assessed. Currently, 341 jobs are at a moderate risk level and 2,836 are at a low risk level. In 2018, the company plans to eliminate or change any task(s) that yield a high-risk score. In 2019, their goal is to make 95 percent of all jobs low-risk.