About TVS Motor Company
TVS Motor Company is a globally recognised leader in the manufacturing of two- and three-wheeler vehicles, known for its strong commitment to quality, innovation, and sustainable mobility. With a robust presence in over 80 countries and advanced manufacturing facilities across India — Hosur, Mysuru, and Nalagarh — and Indonesia, the company is built on a 100-year legacy of Trust, Value, and Service.
As part of its ongoing commitment to employee well-being — including contractor workforce — and the enhancement of occupational health standards, TVS Motor has implemented structured ergonomic assessment programs across assembly lines and auxiliary operations. All new facilities are being designed with ergonomics at the core, minimising risks associated with repetitive movements, twisting, bending, and manual material handling.
Scaling Ergonomic Risk Assessment Across Global Manufacturing
Prior to implementing ErgoEdge, workplace design at TVS Motor was not adequately aligned with ergonomic principles, and anthropometric factors were not systematically considered when deploying employees to workstations. This resulted in increased physical strain — particularly work-related upper limb fatigue — across assembly lines and auxiliary operations.
The approach created three compounding problems:
Workforce Fatigue
Non-ergonomic work design and manual lifting loads caused upper limb fatigue and physical strain among assembly and operations workers across multiple plants.
No Anthropometric Framework
Workstation assignments did not account for anthropometric factors, creating mismatches between task demands and worker physiology that compounded MSD risk over time.
Limited Scalability
Manual assessment methods could not scale across thousands of activities spanning manufacturing and non-manufacturing sites in India and Indonesia.
AI-Powered Ergonomic Assessments with ErgoEdge
TVS Motor Company implemented ErgoEdge to replace manual assessment workflows with a scalable, data-driven approach — covering both manufacturing and non-manufacturing sites across all operations with potential MSD risk.
Record
EHS teams and supervisors recorded workers performing tasks using standard smartphones — no wearable sensors or specialist equipment required.
Assess
ErgoEdge's AI engine processed each video frame-by-frame, calculating ergonomic risk scores across RULA, REBA, NIOSH, and other established methods.
Control
Based on risk scores, targeted kaizens and engineering controls were systematically implemented across plants — aligned to actual ergonomic risk levels.
Each assessment produces comprehensive output: risk severity scoring, body parts at highest risk, 3D posture simulation, improvement tracking, and actionable recommendations — all exported as PDF and Excel reports.
Deployed Across Manufacturing & Non-Manufacturing Sites
Measurable Impact Across the Ergonomics Program
Since adopting ErgoEdge, TVS Motor Company has realised measurable improvements across its ergonomics program — from faster risk identification to improved workforce health outcomes.
Significant Reduction in Assessment Time
Real-time ergonomic evaluations replaced lengthy manual processes, enabling faster risk identification and quicker decision-making across all plants within the same session.
Reduction in OHC Visits
Improved workplace design and targeted ergonomic controls contributed to a noticeable decrease in occupational health centre visits related to discomfort and MSD concerns.
Clearer Risk Communication
ErgoEdge visual risk scoring strengthened communication with leadership, supervisors, and shopfloor employees — enabling faster, better-informed ergonomic decisions.
Reactive → Proactive Safety
Kaizens and engineering controls were systematically implemented based on calculated risk scores, shifting TVS Motor from reactive safety responses to targeted, data-driven prevention.
Ergonomics at the Core of New Facilities
Following ErgoEdge implementation, all new TVS Motor facilities are now being designed with ergonomics built in from the ground up. Anthropometric considerations are prioritised in both workstation design and employee deployment — establishing a scalable standard that prevents MSD risk at source rather than addressing it after the fact.
At TVS Motor Company, workforce well-being is central to our sustainability journey, not an add-on. With ErgoEdge, we moved from conventional assessments to real-time, data-driven ergonomic insights across thousands of activities. This has enabled us to significantly reduce assessment time, minimize OHC visits through proactive interventions, and strengthen communication of risks with all stakeholders. Most importantly, it has helped us implement targeted kaizens and engineering controls aligned with actual ergonomic risk levels — something that was not scalable through manual approaches.
Why TVS Motor Company Chose ErgoEdge
| Capability | How It Helped TVS Motor Company |
|---|---|
| No Sensors or Hardware | Enabled rapid deployment across plants in India and Indonesia without capital expenditure on specialist equipment. |
| AI-Powered RULA, REBA, NIOSH | Delivered consistent, objective ergonomic risk scores across 3,000+ activities — eliminating subjectivity from manual observation-based assessments. |
| Real-Time Video Analysis | EHS teams assessed tasks immediately using smartphones, accelerating the identification of high-risk workstations and enabling same-session decision-making. |
| Visual Risk Communication | 3D posture simulations and colour-coded risk scores made ergonomic data accessible to shopfloor supervisors, plant leadership, and the corporate EHS team. |
| Scalable Cloud Platform | Assessment data from all plants centralised into a single dashboard — enabling group-level visibility and standardisation of ergonomic controls across locations. |
| ISO 27001 Certified | Met TVS Motor's enterprise data security requirements — no personal worker information collected, with facial masking applied to all video content. |
Scale Your Ergonomics Program with AI
ErgoEdge helps EHS teams at global manufacturers assess ergonomic risks using only a smartphone and a cloud connection — no sensors, no hardware, no travel required.
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