India being one of the world’s largest automobile manufacturers provides a massive platform for establishing large numbers of chemical conversion coating industries. Industrial shop-floors dealing with the surface conversion coating processes are not well-planned and ergonomically sound. In many instances, the predominance of the sub-standardized workplace, work-accessories and process planning in these factories are not only affecting the performance, efficiency and wellbeing of the workers but also the productivity. To address these issues, the present research was carried out for ergonomic evaluation of the existing scenario of working conditions in factory shop-floors and to come up with the user friendly design of workstations/work-accessories, better process layout and operation sequences with the intention of improved occupational health, safety and productivity. For implementation of the proposed design and checking its effectiveness, virtual ergonomics technique using digital human model was adopted. Ergonomic intervention strategies reported in the present research would be very useful for redesigning of existing plating factories and setting up similar new factories. © Springer International Publishing AG 2018.