capstone design working place improvement by using “hfe” - presenter : noh il-do 20082460...

Capstone design

Working place improvement by using “HFE”

- Presenter : Noh il-do 20082460 노일도

20092358 임정욱20092388 정의현

Contents

1. Motive of Research

3. Project Plan

4. Detailed information -Detailed information -Process(Press / Milling) -Analytical methods

5. Gantt chart

2. What is HFE (Human Factors Engineering)?

1. Motive of Research

Small and Middle Sized Company with poor work-ing conditions

project

How to solve this situation ?

We use a HFE

Dangerous,Labored work,Uncomfortable

position

2. What is “HFE”?• HFE is appropriate and necessary skills to

be a good fit for a job is a job design.

Environment Machinery, equipment

Human

Safety, comfort, convenience, effectiveness, efficient

by designing for human

3.Project plan

Risk Average of

same working

corporates.

Analysis / evaluation

Presented a realistic

improvement

Ergonomic workplace improvement.

3.Project plan

5. Improvement

4. Evaluation& Selection Solution

1. Collecting Data

2. HFE Analysis

3.compared/analysis to the risk average

Completion of the project

4.Detailed information

Find out each company risks,

collect data thus which is the best way to improve

system.

ChooseThe Motion Analysis,

SimulationVisit to

company

4week 5week 6week

4.Detailed informationVisit to company

Company name: Yushin

Type of business: Military Supplies

The number of employees: 50 employees

Sales: Two billion WON

working environment : Poor surroundings

Location: Hanam industrial complex

4.Detailed informationData arrange(Photos & Videos)

PRESS

MILLING

welding

handle

4.Detailed information

Chart Title in here

Analytical methodsBase on “HFE”evaluation tools.

Evaluation Tool Type of Business ETC

RULA Position working process ENGLAND/1993

NLE Weight handle working NIOSHA1981/1991

VDT Work Environment CHECKLIST

5.Gantt chart

Chart Title in here

1 주 2 주 3 주 4 주 5 주 6 주 7 주 8 주 9 주 10 주 11 주 12 주

Schedule

Data Collection

Data Analysis

Compared / analysis to the risk average

Improvement derived

Evaluation & selec-tion

Final presentation

Contents

1. Data Collection -Question investigation

-Photos & videos

2. Data Comprehensive -Results of the survey data -Harmful factor

3. Data measure & Plan -Detailed information

4. Gantt chart

Top 10 Basic rules “HFE” Score Card

1. Comfortable fit Uncomfortable fit (Wrist / Neck / Waist)

2. Do not pressure over Power Over power

3. Cut Down on many things Over motion

4. Easy to get STH Can not get to STH

5. A vaild height to work Too low STH

6. Get rid of stress Static posture

7. Reduce on Body pressure Body pressure

8. Clear up Surrounding Not enough to clean up

9. Exercise, Stretching Needs Exercise, Strething

10. A pleasant environment to work Poor lighting equipment

Question investigation1. Motive of Research

Target : Each workerWorkingEnviro-ment

Do you think self – satisfaction about working place?                                           How about working place?(Dust, Noise, Scent, Temperature) How about average working time?

ETC : 　

Work poses

inconve-nient

How about work poses? (Shoulder, Wrist, Waist, Leg) Have you ever thought about work poses are uncomfort-able?            If your working long time after that any pains?                          Which part are painful? How about pain degree? : (Top , Middle , Low)

ETC : 　Improve-

mentRequire-

ment

Now your part can be improve Safty system?  Which part already improvement?

Which part do you want to improve?

ETC :

1. Data collection 2. data comprehensive 3. Data measure & plan 4. Gantt chart

Question investigation

1. Data collection 2. data comprehensive 3. Data measure & plan 4. Gantt chart

Data arrange(Photos & Videos)

PRESS

MILLING

Press process

milling Process

milling Process2

0% 10% 20% 30% 40% 50% 60% 70% 80% 90%

1. Data collection 2. data comprehensive 3. Data measure & plan 4. Gantt chart

Results of the survey data

Press

Posture

position of Work In Process

Waist bending

Ways of working

Milling(1)

Posture position of

Work In Process

placement of a work tool

Oil Waist bending

Work rate Workspace

Milling(2)

Posture position of

Work In Process Oil

Waist bending body condition

Ways of working

placement of a work tool

1. Data collection 2. data comprehensive 3. Data measure & plan 4. Gantt chart

Harmful factor

Analysis?(X)

1. Data collection 2. data comprehensive 3. Data measure & plan 4. Gantt chart

Survey

Video record-

ing

Analytical plan 1. Data collection 2. data comprehensive 3. Data measure & plan 4. Gantt chart

Analytical methods

RULA JSIbasis techniques Another

analysis

Graph Analyze

characteristics diagram 

Mind Mapping

5W1H

1. Data collection 2. data comprehensive 3. Data measure & plan 4. Gantt chart

Gantt chart

1 주 2 주 3 주 4 주 5 주 6 주 7 주 8 주 9 주 10 주 11 주 12 주

Schedule

Data Collection

Data Analysis

Compared / analysis to the risk average

Improvement derived

Evaluation & selec-tion

Final presentation

1. Data collection 2. data comprehensive 3. Data measure & plan 4. Gantt chart

Contents1. Ergonomic measurement

-RULA -JSI

2. Data Analysis -Graph Analysis

-Characteristics diagram -Mind mapping

3. Gantt chart

상박 하박

손목1 2 3 4

손목 비틀림 손목 비틀림 손목 비틀림 손목 비틀림

1 2 1 2 1 2 1 2

1

1 1 2 2 2 2 3 3 3

2 2 2 2 2 3 3 3 33 2 3 3 3 3 3 4 4

21 2 3 3 3 3 4 4 42 3 3 3 3 3 4 4 4

3 3 4 4 4 4 4 5 5

3

1 3 3 4 4 4 4 5 5

2 3 4 4 4 4 4 5 53 4 4 4 4 4 5 5 5

4

1 4 4 4 4 4 5 5 5

2 4 4 4 4 4 5 5 53 4 4 4 5 5 5 6 6

51 5 5 5 5 5 6 6 72 5 6 6 6 6 7 7 7

3 6 6 6 7 7 7 7 8

6

1 7 7 7 7 7 7 8 9

2 8 8 8 8 8 9 9 93 9 9 9 9 9 9 9 9

Total score

[3 ]+1+04 more times minute iterations. : +1

Less than 2kg load (intermittent) : +0

1. Ergonomic measurement 2. Data Analysis 3. Gantt chart

RULA Press process

1. Ergonomic measurement 2. Data Analysis 3. Gantt chart

RULA Press process

목

몸통

1 2 3 4 5 6

다리 다리 다리 다리 다리 다리

1 2 1 2 1 2 1 2 1 2 1 2

1 1 3 2 3 3 4 5 5 6 6 7 7

2 2 3 2 3 4 5 5 5 6 7 7 7

3 3 3 3 4 4 5 5 6 6 7 7 7

4 5 5 5 6 6 7 7 7 7 7 8 8

5 7 7 7 7 7 8 8 8 8 8 8 8

6 8 8 8 8 8 8 9 9 9 9 9 9

Rotated so that the body :+1

Pick the bottom of the legs and feet, so the balance is

good. : +1

Total Score[2]+1+0

4 more times minute iterations. : +1Less than 2kg load (intermittent) : +0

1. Ergonomic measurement 2. Data Analysis 3. Gantt chart

RULA Press process

1 2 3 4 5 6 7+

1 1 2 3 3 4 5 5

2 2 2 3 4 4 5 5

3 3 3 3 4 4 5 6

4 3 3 3 4 5 6 6

5 4 4 4 5 6 7 7

6 4 4 5 6 6 7 7

7 5 5 6 6 7 7 7

8+ 5 5 6 7 7 7 7

Score A (4) + MUSCLE (1) + FORCE (0) = SCORE(4)

Score B (2)

+

MUSCLE (1)

+

FORCE (0)

= SCORE

(3)Grand Score (3)

1. Ergonomic measurement 2. Data Analysis 3. Gantt chart

RULA Press process

Action level 3 : A score of 5 or 6 indicates that investigation and changesare requried soon. ( 빠른작업개선 )

Action level 4 : A score of 7 indicates that investigation and changes are required immediately. ( 즉시작업개선 )

# The requirements for action into which the grand scores are divided is summarized into Action levels as follows :

Action level 2 : A score of 3 or 4 indicates that further investigation is needed and changes ma be required. ( 관찰요망 )

Action level 1 : A score of 1 or 2 indicates that postures is acceptable If it is not maintained or repeated for long periods. ( 수용가능 )

1. Ergonomic measurement 2. Data Analysis 3. Gantt chart

JSI Press process

Rating 작업강도

매회당

긴장기간

백분율 (%)

분당횟수

( 회 )손 / 손목의

자세작업의 속도

하루

작업시간

( 시간 )

1약함

(1)<10(0.5)

<4(0.5)

매우 좋음

(1)매우 느림

(1)<1

(0.25)

2다소 힘듬

(3)10-29

(1)4-8(1)

좋음

(1)느림

(1)1-2

(0.5)

3힘듬

(6)30-49(1.5)

9-14(1.5)

보통

(1.5)보통

(1)2-4

(0.75)

4매우 힘듬

(9)50-79

(2)15-19

(2)나쁨

(2)빠름

(1.5)4-8(1)

5한계치에

가까움

(13)

>80(3)

>20(3)

아주 나쁨

(3)매우 빠름

(2)>8

(1.5)

Assessment results and action steps

JSI = 1 * 0.5 * 2 * 1.5 * 1 * 1.5 = (2.25)

Ⓞ JSI SCORE ≤ 3 : Safe working Ⓞ 4 ≤ JSI SCORE < 7 : Jobs are likely to be caused by upper limb disorders.

Ⓞ JSI SCORE ≥ 7 : Very risky

1. Ergonomic measurement 2. Data Analysis 3. Gantt chart

RULA Milling process

상박 하박

손목1 2 3 4

손목 비틀림 손목 비틀림 손목 비틀림 손목 비틀림

1 2 1 2 1 2 1 2

1

1 1 2 2 2 2 3 3 3

2 2 2 2 2 3 3 3 3

3 2 3 3 3 3 3 4 4

2

1 2 3 3 3 3 4 4 4

2 3 3 3 3 3 4 4 4

3 3 4 4 4 4 4 5 5

3

1 3 3 4 4 4 4 5 5

2 3 4 4 4 4 4 5 5

3 4 4 4 4 4 5 5 5

4

1 4 4 4 4 4 5 5 5

2 4 4 4 4 4 5 5 5

3 4 4 4 5 5 5 6 6

5

1 5 5 5 5 5 6 6 7

2 5 6 6 6 6 7 7 7

3 6 6 6 7 7 7 7 8

6

1 7 7 7 7 7 7 8 9

2 8 8 8 8 8 9 9 9

3 9 9 9 9 9 9 9 9

Total score

[4 ]+1+04 more times minute iterations. : +1Less than 2kg load (intermittent) : +0

1. Ergonomic measurement 2. Data Analysis 3. Gantt chart

RULA Milling process

목

몸통

1 2 3 4 5 6

다리 다리 다리 다리 다리 다리

1 2 1 2 1 2 1 2 1 2 1 2

1 1 3 2 3 3 4 5 5 6 6 7 7

2 2 3 2 3 4 5 5 5 6 7 7 7

3 3 3 3 4 4 5 5 6 6 7 7 7

4 5 5 5 6 6 7 7 7 7 7 8 8

5 7 7 7 7 7 8 8 8 8 8 8 8

6 8 8 8 8 8 8 9 9 9 9 9 9

Rotated so that the body :+0

Pick the bottom of the legs and feet, so the balance is

bad. : +2

Total Score[4]+1+0

4 more times minute iterations. : +1Less than 2kg load (intermittent) : +0

1. Ergonomic measurement 2. Data Analysis 3. Gantt chart

RULA Milling process

1 2 3 4 5 6 7+

1 1 2 3 3 4 5 5

2 2 2 3 4 4 5 5

3 3 3 3 4 4 5 6

4 3 3 3 4 5 6 6

5 4 4 4 5 6 7 7

6 4 4 5 6 6 7 7

7 5 5 6 6 7 7 7

8+ 5 5 6 7 7 7 7

Score A (4) + MUSCLE (1) + FORCE (0) = SCORE(5)

Score B (4)

+

MUSCLE (1)

+

FORCE (0)

= SCORE

(5)Grand Score (6)

1. Ergonomic measurement 2. Data Analysis 3. Gantt chart

RULA Milling process

Action level 3 : A score of 5 or 6 indicates that investigation and changesare requried soon. ( 빠른작업개선 )

Action level 4 : A score of 7 indicates that investigation and changes are required immediately. ( 즉시작업개선 )

# The requirements for action into which the grand scores are divided is summarized into Action levels as follows :

Action level 2 : A score of 3 or 4 indicates that further investigation is needed and changes ma be required. ( 관찰요망 )

Action level 1 : A score of 1 or 2 indicates that postures is acceptable If it is not maintained or repeated for long periods. ( 수용가능 )

1. Ergonomic measurement 2. Data Analysis 3. Gantt chart

JSI Milling process

Rating 작업강도

매회당

긴장기간

백분율 (%)

분당횟수

( 회 )손 / 손목의

자세작업의 속도

하루

작업시간

( 시간 )

1약함

(1)<10(0.5)

<4(0.5)

매우 좋음

(1)매우 느림

(1)<1

(0.25)

2다소 힘듬

(3)10-29

(1)4-8(1)

좋음

(1)느림

(1)1-2

(0.5)

3힘듬

(6)30-49(1.5)

9-14(1.5)

보통

(1.5)보통

(1)2-4

(0.75)

4매우 힘듬

(9)50-79

(2)15-19

(2)나쁨

(2)빠름

(1.5)4-8(1)

5한계치에

가까움

(13)

>80(3)

>20(3)

아주 나쁨

(3)매우 빠름

(2)>8

(1.5)

Assessment results and action steps

JSI = 1 * 1 * 1.5 * 2 * 1 * 1.5 = (4.5)

Ⓞ JSI SCORE ≤ 3 : Safe working Ⓞ 4 ≤ JSI SCORE < 7 : Jobs are likely to be caused by upper limb disorders.

Ⓞ JSI SCORE ≥ 7 : Very risky

1. Ergonomic measurement 2. Data Analysis 3. Gantt chart

Analysis summarized table

Press process Assembly Process

RULA measure-ments 3 Point 6 Point

Result Observed demand Work needs to be improved

JSI measure-ments

2.25 Point 4.5 Point

Result Safe working Visible and poten-tially dangerous.

Press process milling Process

65%55%

90%

70%

30% 30%20%

15%

Workplace satisfaction Posture satisfactionExperienced pain Whether safety improvements

Statistical graph analysis 1. Ergonomic measurement 2. Data Analysis 3. Gantt chart

Press processmilling Process

0%

10%

20%

30%

40%

50%

60%

satisfaction

Overall Statistical graph 1. Ergonomic measurement 2. Data Analysis 3. Gantt chart

Safety index table

Press process Milling Process

RULA measure-ments 3 Point 6 Point

JSI measure-ments 2.25 Point 4.5 Point

Average (Risk) 2.625 Point 5.25 Point

Average (safety index)

10 – (Risk)7.375 Point 4.75 Point

1. Ergonomic measurement 2. Data Analysis 3. Gantt chart

Press processmilling Process

0123456789

10

7.375

4.750

Safety index

Measurement results graphs safety levels 1. Ergonomic measurement 2. Data Analysis 3. Gantt chart

Press processmilling Process

0

2

4

6

8

10

Safety index

comparison of the results 1. Ergonomic measurement 2. Data Analysis 3. Gantt chart

Press processmilling

Process

0%

20%

40%

60%

satisfaction

Gantt chart

1 주 2 주 3 주 4 주 5 주 6 주 7 주 8 주 9 주 10 주 11 주 12 주

Schedule

Data Collection

Data Analysis

Compared / analysis to the risk average

Improvement derived

Evaluation & selec-tion

Final presentation

1. Ergonomic measurement 2. Data Analysis 3. Gantt chart

Contents

1. Course of Alternative derivation

-Fishbone diagram-Risk and Injurious factor

2. Derive an alternative method- The use of techniques

- Derived risks and alternatives

3. Gantt chart

Press process

Risk?

Machinery accident

Drwosiness Fatigue

Mechanical failure

Material

Weight

TemperatureBody condition

Proficiency

Work environment

Fishbone diagram

Milling process(1)

Risk? Safety?

Drowsiness

Machinery accident

Time

keep in step

Work environment

Body condition

Material

Fatigue

Proficiency

Weight

Fishbone diagram

Fishbone diagram

Milling process(2)

Risk? Safety?

Work environment

Time

keep in step

Mechanical failure

Proficiency

Material

Drowsiness

Weight

Machinery accident

Body condition

For risk classification

Musculoskeletal

Mechanical

Human

Substance.

Environmental

Administrative

Risk and Injurious factor

Brain Storming Mind Melding 5W1H

Methodology

Rating Type Hazards and disasters form

Mechanical- Accidents due to faulty press machine

- Physical damage caused by mechanical noise

Human- Lack of awareness of worker safety

- Physical properties due to the uncomfortable task

Substance.

Environmental

- Cleanliness of press work

- Noise and communication of foreign workers

- Factory of noise and dust

- Slip the bottom shock

- State security tools

Administrative- Establish safety measures

- Safety and lack of safety training

- Accidents due to lack of stretching

Hazards and disasters form Press process

Measures to improve

- Operator training in preparation for machine fault

- Payment clean earplugs and safety tools

- 5S activities and worker training

- Safety training and risk cover

- Safety management and operator training

- Worker Safety Management Training

- Considering the physical characteristics Tool Supply

- Designation and Safety management personnel and managers communicate

- Managers through training

Derivation of improvement Press process

Hazards and disasters form Milling Process (1)

Rating Type Hazards and disasters form

Mechanical- Safety device for lack of working tools

- The size of a woman with a big tool

- Physical damage due to incorrect use of tools

Human- Improper working women hagieneun

- Older workers

- Lines due to the psychological insecurity

Substance.

Environmental

- A narrow bench

- Disorganized workspace.

- Lack of awareness of safety equipment

- Loud noise

- Cotton gloves skin damage caused by the absorption of the oil

Administrative- Insufficient number of managers

- Safety and lack of education

- Accidents due to lack of stretching

Measures to improve

- Provide a tool equipped with safety devices

- Size adjustable providing tools

- On-site safety training

- More extensive than the current bench payments

- Provide clean ear

- Required to provide on-site work gloves

- Working to meet the physical conditions

- Periodically conduct counseling

- Increasing number of on-site management

- Safe exercises carried out at least twice a day

Derivation of improvement Milling Process (1)

Combined arrangementPress process Milling

Process(1)Milling

Process(2)

RULA measure-ments 3 Point 6 Point 6 Point

JSI measure-ments 2.25 Point 4.5 Point 6 Point

Average (Risk) 2.625 Point 5.25 Point 6 Point

Average (safety index)

10 – (Risk)7.375 Point 4.75 Point 4 Point

Gantt chart

1 주 2 주 3 주 4 주 5 주 6 주 7 주 8 주 9 주 10 주 11 주 12 주

Schedule

Data Collection

Data Analysis

Compared / analysis to the risk average

Improvement derived

Evaluation & selec-tion

Final presentation

Thank You!