Due to unsatisfactory productivity, a large company in the Swedish man
ufacturing industry decided to rationalize their assembly system. The
intended rationalization comprised several changes with deliberate erg
onomic implications, The main aim of the present study was to evaluate
the impact of the rationalization on the physical work load of the op
erators, The work load was assessed before and after the changes using
expert observations, company records and direct technical measurement
s, The results indicate that the intervention led to only minor change
s in muscle load, body postures and movement patterns, Several of the
planned initiatives were never implemented, e.g. teaching the workers
multiple skills and designing work stations at which a major part of t
he assembly sequence could be performed, This was mainly due to a poli
cy revision caused by changes in the market situation, In spite of the
company's original intentions, the revised production system containe
d only minor ergonomic improvements, Thus, the realization of the ergo
nomic potential in a rationalization seems to depend on management cul
ture, as well as factors outside the company.