Ergonomic Risk Factors and Mitigation Strategies in a Semiconductor Manufacturing Company: A Case Study

Abstract

Workplace ergonomics aims to optimize workstation designs and tools to enhance safety, efficiency, and productivity while minimizing the risk of injuries. In industries like semiconductor manufacturing, repetitive tasks have been identified as key contributors to musculoskeletal disorders (MSDs), leading to conditions such as back pain, neck strain, and repetitive strain injuries. This study investigates ergonomic risks in the wafer patterning process using an Initial Ergonomic Risk Assessment (ERA) and Advanced ERA tools. The Nordic Musculoskeletal Questionnaire (NMQ) was used to collect data, revealing that workers reported discomfort in areas such as the neck, upper and lower back, wrists, thighs, and legs. The Initial ERA identified wafer patterning as the highest risk task. Advanced ERA findings, with REBA scores of 9 and 10, and ART scores indicating moderate to severe risks (13 and 12 for the left arm, 26 and 25 for the right arm), confirmed the significant ergonomic challenges in this process. A root cause analysis using the fishbone diagram further supported these findings. To mitigate these risks, the study recommends engineering controls, such as improving workstation designs and tools, alongside administrative controls, including posture training, exercise programs, and task rotation. These suggestions aim to reduce exposure to WMSD risk factors and enhance worker well-being. Ultimately, these measures will contribute to a safer and more efficient workplace for employees engaged in wafer patterning, enhancing both productivity and worker health in the long term.