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Introduction: Awkward postures that contribute to low back overload are commonly observed in the manufacturing of textile products for domestic use, such as sheet sewing. Trunk flexion while seated, often to reach raw materials placed at floor level, is a frequent occurrence in Brazilian production systems. Conversely, there is often a cultural resistance within organizations to adopt preventive measures, as leaders frequently assume that changes to the production system may negatively impact productivity.

This study aimed to implement low-cost ergonomic improvements to reduce physical overload, eliminate non-value-adding postures, safeguard workers’ health, preserve working hours, and enhance process speed and efficiency following Lean Manufacturing principles.

Methods: A 55 cm-high bench was introduced to elevate fabric rolls previously positioned at ground level. The intervention was applied in a production unit with 38 employees (mean age = 30.6 years; SD = 6), from a textile company in a country town of São Paulo, Brazil, including 32 women and 6 men. Data collection involved video recordings and comparative time-motion analysis before and after the intervention.

Results: The implementation eliminated lateral trunk flexion movements, previously averaging 250 instances per day per worker – amounting to approximately 55,000 movements eliminated annually per worker. Furthermore, the time required to retrieve materials from the bench, compared to the floor, was reduced by 4 seconds.

Discussion: For a team of 38 workers, this results in a daily saving of 38,000 seconds. Considering a cycle time of 118 seconds, this corresponds to an increase of 322 pieces/sheets produced per day.

Conclusion: The results demonstrate that low-cost ergonomic improvements are effective in reducing physical overload, leading to enhanced worker well-being, improved operational efficiency, and the strengthening of a culture focused on prevention within the organization.