New easy to use postural assessment method through visual management

•The objective of this study is to develop a new easy-to-use postural assessment tool.•The methodology apply a successful set of visual maps to guide the analyst during the postural assessment evaluation.•We test the new methodology and evaluate its performances in a car component assembly system.•The results show the potential of the methodology when compared with the well-known OCRA method.

Earlier studies have demonstrated the strong relationships between manual assembly work with a high repetition level and the presence of repetitive strain injuries (RSI) or repetitive motion illnesses (RMI). Moreover, recent works have also correlated the high physical load level in assembly lines with an increased number of quality defects in finished products. Thus, the ergo-quality level of a manual workstation needs to be carefully monitored not only to respond to the legislation but first of all to ensure a high system productivity level in the medium-term perspective. The objective of this study was to develop and test a new easy-to-use postural assessment tool and its performance in a car component assembly system. The results show the promising potential of the methodology particularly when compared with the well-known OCRA method.