UNIVERSITI TEKNIKAL MALAYSIA MELAKA
ERGONOMIC ASSESSMENT IN MANUFACTURING INDUSTRY
(JATI BERINGIN SDN. BHD)
This report submitted in accordance with requirement of the Universiti Teknikal
Malaysia Melaka (UTeM) for the Bachelor Degree of Manufacturing Engineering
(Manufacturing Management) with Honours.
by
MOHAMAD BIN ISMAIL
FACULTY OF MANUFACTURING ENGINEERING
2010
UTeM Library (Pind.1/2005)
SULIT
TERHAD
TIDAK TERHAD
(Mengandungi maklumat yang berdarjah keselamatan atau kepentingan Malaysia yang termaktub di dalam
AKTA RAHSIA RASMI 1972)
(Mengandungi maklumat TERHAD yang telah ditentukan
oleh organisasi/badan di mana penyelidikan dijalankan)
(TANDATANGAN PENULIS)
Alamat Tetap: 1246-B, KG. MASJID BATU BUROK
20400, KUALA TERENGGANU
TERENGGANU
Tarikh: _______________________
Disahkan oleh:
(TANDATANGAN PENYELIA)
Cop Rasmi:
Tarikh: _______________________
* Tesis dimaksudkan sebagai tesis bagi Ijazah Doktor Falsafah dan Sarjana secara penyelidikan, atau disertasi bagi pengajian secara kerja kursus dan penyelidikan, atau Laporan Projek Sarjana Muda (PSM). ** Jika tesis ini SULIT atau TERHAD, sila lampirkan surat daripada pihak berkuasa/organisasi berkenaan dengan menyatakan sekali sebab dan tempoh tesis ini perlu dikelaskan sebagai SULIT atau TERHAD.
BORANG PENGESAHAN STATUS TESIS*
UNIVERSITI TEKNIKAL MALAYSIA MELAKA
JUDUL: ERGONOMIC ASSESSMENT IN MANUFACTURING INDUSTRY
(JATI BERINGIN SDN.BHD)
SESI PENGAJIAN: 2009-2010 Saya _____________________________________________________________________ mengaku membenarkan tesis (PSM/Sarjana/Doktor Falsafah) ini disimpan di Perpustakaan Universiti Teknikal Malaysia Melaka (UTeM) dengan syarat-syarat kegunaan seperti berikut:
1. Tesis adalah hak milik Universiti Teknikal Malaysia Melaka. 2. Perpustakaan Universiti Teknikal Malaysia Melaka dibenarkan membuat salinan
untuk tujuan pengajian sahaja. 3. Perpustakaan dibenarkan membuat salinan tesis ini sebagai bahan pertukaran
antara institusi pengajian tinggi.
4. **Sila tandakan (√)
MOHAMAD BIN ISMAIL
i
DECLARATION
I hereby, declared this report entitled “Ergonomic Assessment in Manufacturing
Industry (Jati Beringin sdn. Bhd)” is the results of my own research except as cited in
references.
Signature : ………………………………………….
Author’s Name : MOHAMAD BIN ISMAIL
Date : …………………………………………
ii
APPROVAL
This report is submitted to the Faculty of Manufacturing Engineering of UTeM as a
partial fulfillment of the requirements for the degree of Bachelor of Manufacturing
Engineering (Manufacturing Management) with Honours. The member of the
supervisory committee is as follow:
(Signature of Supervisor)
………………………………
(Official Stamp of Supervisor)
iii
ABSTRACT
The title of this project is “ergonomic assessment manufacturing industry”. The projects
discuss about the technique for easy the worker to do their job in manufacturing
company, Jati Beringin Sdn. Bhd. The project focuses to analyze working posture and
low back pain using RULA method. This project will analyze, revise, and recommend a
new technique as solution to improve present working posture. The data will collect
through factory visits, interview and observation at the process assemble line. From the
data collected RULA method will be analyzed and propose the solution. Finally, new
conveyor table will be proposed and the effectiveness will be measured by comparing
before and after using new design. The project also is carrying out of noise assessment
and lighting assessment.
iv
ABSTRAK
Tajuk projek ini ialah "taksiran ergonomic dalam industry pembuatan". Projek ini
membincangkan tentang teknik untuk memudahkan pekerja melakukan kerja mereka
dalam syrikat perkilangan, Jati Beringin Sdn. Bhd. Tumpuan projek untuk menganalisa
postur bekerja dan kesakitan bahagian belakang menggunakan kaedah RULA. Projek ini
akan dianalisa, disemak, dan mencadangkan satu teknik baru sebagai penyelesaian bagi
meningkatkan postur bekerja sekarang. Data akan diambil melalui lawatan kilang, soal
selidik dan pemerhatian diproses pemasangan produk. Daripada data yand diambil,
kaedah RULA akan dianalisiskan serta cara penyelesaiannya. Akhirnya, tempat kerja
baru akan dicadangkan dan keberkesanannya akan diukur dengan menbandingkan
tempat kerja yang baru dan yang lama. Projek ini juga membincangkan tentang
kebisingan dan pengcahayaan.
v
DEDICATION
This project is dedicated to my beloved family and all friend who provide the most
supportive atmosphere instead of loving and caring
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ACKNOWLEDGEMENT
Utmost gratefulness to The Almighty ALLAH SWT for the abundant blessing and favours for me to accomplished the research Projek Sarjana Muda.
I would like to extend my warmest gratitude to my supervisor, Mr. Nor Akramin B.
Mohamad for his excellent supervision, invaluable guidance, advice trust, constant help,
support, encouragement and assistance towards me throughout this project.
I would also like to thank Jati Beringin Sdn. Bhd. and their staff as they provided me to
place, time and always shows their sincere kindness in helping and gave me useful
information.
Ina addition, I would like to thank my family whose endless encouragement gave me the
added strength and inspiration to carry out this project to the best of my ability. At the
same time, I would like o thank my friends and course mate for their constructive
comments throughout the accomplishment of this project.
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TABLE OF CONTENTS
Declaration i
Approval ii
Abstract iii
Abstrak iv
Dedication v
Acknowledgement vi
List of Tables xi
List of Figure xii
List Abbreviations xiv
Appendix xv
1.0 INTRODUCTION
1.1 Background of study 1
1.2 Problem Statement 2
1.3 Objective 2
1.4 Scope 3
1.5 Potential Benefits of Study 3
1.6 Structure of the Report 4
viii
2.0 LITERATURE REVIEW
2.1 History of Ergonomics 6
2.2 Manual material handling 8
2.2.1 Lifting tasks 9
2.3 Musculoskeletal Disorders 10
2.3.1 Musculoskeletal Problem in Sitting and Standing 11
2.3.2 Effects of MSD on productivity efficiency 12
2.4 Low back pain 12
2.4.1 Back pain and muscular fatigue 13
2.4.2 Other Causes of Back Pain 14
2.4.3 Spinal Problems in Standing 15
2.5 Workstation design 15
2.6 Rapid Upper Limb Assessment (RULA) 17
2.7 Noise 19
2.8 Light 20
2.9 Illumination 21
2.10 National Institute of Occupational Safety and Heath
(NIOSH) 21
2.11 Research for Ergonomics 23
3.0 METHODOLOGY
3.1 Planning of Study 26
3.1.1 Define problem 29
3.1.2 Define the objective, scope and problem of
the study 29
3.1.3 Visit and observation the current
production at Manufacturing industry 29
ix
3.1.4 Literature Review 30
3.1.5 Data Collection 30
3.1.5.1 Semi-Structure Interview 30
3.1.6 Data Verification 31
3.1.7 RULA Method 31
3.1.7.1 RULA Analyze Procedure 31
3.1.7.2 Procedures of Experiment 33
3.1.8 Data collection noise assessment 33
3.1.9 Data collection lighting assessment 34
3.2 Conclusion and Recommendation Improvement 35
3.3 Conclusion 35
3.4 Research Methodology 35 4.0 RESULT AND DISCUSSION
4.1 Introduction 38
4.2 Data Collection 39
4.2.1 Observation 39
4.2.2 Semi Structure Interview 41
4.3 Ergonomics Assessment 43
4.3.1 RULA Result before Implementation 43
4.3.1.1 Result from Real Situation 44
4.3.2 Noise Assessment 49
4.3.2.1 Data Noise Assessment 50
4.3.3 Lighting Assessment 53
4.3.3.1 Data Lighting Assessment 55
4.4 Proposal for Ergonomics Improvement 59
4.4.1 Workspace Design 59
4.4.1.1 Work surface height 59
4.4.1.2 Work Area 60
4.4.2 Analysis Data from Workspace Design 61
x
4.4.3 Proposal Drawing for New Workstation Design 62
4.4.4 Training 65
4.4.5 Proposal Improvement for Noise and Lighting
Assessment 67
4.5 Result after Improvement 68
4.5.1 Result after Workspace Design Improvement 68
4.5.2 Ergonomics Awareness Improvement 71
5.0 CONCLUSION AND RECOMMENDATION
5.1 Introduction 72
5.2 Observation the Result Findings 72
5.3 Limitation of the Project 73
5.4 Recommendation of the Project 73
5.5 Conclusion 74
REFERENCES 76
xi
LIST OF TABLES
2.1 Safe noise level recommended by OSHA 20
2.2 Summary of journal 23
3.1 The Description of methodology 36
4.1 Situation the operator does the job 39
4.2 Posture risk assessment for group A 46
4.3 Posture risk assessment for group B 47
4.4 Scoring for group A body part 48
4.5 Scoring for group B body part 48
4.6 Grand score 48
4.7 Data collection for noise level at morning 50
4.8 Data collection for noise level at afternoon 51
4.9 Data collection for noise level at evening 52
4.10 The occupational Safety and Health Administration 53
4.11 Data collection for lighting level at the morning 55
4.12 Data collection for lighting level at the afternoon 56
4.13 Data collection for lighting level at the evening 57
4.14 Table of light level 58
4.15 Training details 65
4.16 Example training at the factory 66
4.17 Posture risk assessment for group A 69
4.18 Posture risk assessment for group B 70
4.19 Scoring for group A body part 70
4.20 Scoring for group B body part 71
4.21 Grand score 71
xii
LIST OF FIGURES
2.1 Method of ergonomic assessment 8
2.2 Example of manual material handling 9
2.3 Example of low back pain 13
2.4 Task requirement workstation design 16
2.5 Recommended work surface for standing work 16
2.6 Wrist posture is determined by the height an orientation of
the work surface and the shape of the hand tool 17
2.7 Example table of ergoweb of RULA 19
2.8 Example of Table ergoweb NIOSH 22
3.1 Project methodology flow chart 28
3.2 Selection of RULA in the Job Evaluator Toolbox 4.0 32
3.3 Posture risk factor assessment for Group A
(upper arm, lower arm, and wrist) 32
3.4 Posture risk factor assessment for Group B
(neck, trunk and legs) 33
3.5 Digital Sound Level Meter 34
3.6 Lux Meter 34
3.7 Description of flow chart from methodology 37
4.1 Graph of Semi-Structure Interview 43
4.2 The workers do the job 44
4.3 Data collection using RULA software 44
4.4 Digital Sound Level Meter 49
4.5 Data collection for Noise 49
4.6 Distribution of noise level at morning 50
4.7 Distribution of noise level at afternoon 51
4.8 Distribution of noise level at evening 52
4.9 Lux Meter 54
xiii
4.10 Data collection for lighting 54
4.11 Distribution of lighting level at morning 55
4.12 Distribution of lighting level at afternoon 56
4.13 Distribution of lighting level at evening 57
4.14 Recommended work surface for standing work 59
4.15 Normal and maximum working areas 60
4.16 Example the conveyor 62
4.17 View from front, side and top 63
4.18 The measure of the conveyor 64
4.19 New situation the worker assemble the part 68
xiv
LIST OF ABBREVIATION
RULA - Rapid Upper Limb Assessment
NIOSH - National Institute for Occupational Safety and Health
MMH - Manual material handling
MSDs - Musculoskeletal Disorders
CTDs - Cumulative trauma disorders
RSI - Includes repetitive strain injuries
OS - Overuse strain
OOS - Occupational overuse syndrome
RMDs - Repetitive motion disorders
WRMSD - Work related musculoskeletal disorders
EMG - Electromyography
OSHA - Occupational Safety and Health Administration
xv
APPENDICES
Appendix A: Gantt chart PSM
Appendix B: Table Result RULA Method
Appendix C: References Diagram for RULA Analysis
Appendix D: Semi Structure Interview
Appendix E: Drawing conveyor
1
CHAPTER 1
INTRODUCTION
This chapter explains the background of the study which consists the study background,
problem statement, objective, scope of the project.
1.1 Background of study
Ergonomics, which referred to as human engineering, is designed to improve the
relationship between workers and the work environment. In order to know how
effectively the factory is utilizing ergonomics or exactly where to begin when first
implementing ergonomics, need to undergo an ergonomic assessment. An ergonomic
assessment of workplace can reveal any unsafe or problem areas, identify ergonomic
solutions, and help the implement an ergonomic plan of action that will improve the
overall ergonomics in the factory. Environment comfortable can increase productivity,
reduced injuries, and costly downtime.
This project aim to run an ergonomic assessment in manufacturing industry. Ergonomic
assessment in this project more to improve the workplace, equipment, environment and
help to improve the productivity while assuring the safety, health and well being of the
workers. From the data collected, the analysis will be done to determine the problem.
2
The improvement proposed by using the ergonomic assessment to reduce the injuries
risk by Jati Beringin Sdn.Bhd. workers.
1.2 Problem Statement
At the Jati Beringin Sdn.Bhd, the workers do their task with no comfortable condition.
The workers will do the assembling while sitting for a long time to perform their tasks.
The situation can give a risk for the workers and also will be effects the performance.
This situation leads to tiredness and back pain for the workers. So, they also have take
much rest from make the job. Also, the working environment is not comfortable cause of
noise and lighting assessment. In this case, of course can increase the cost of doing
directly and indirectly. Direct cost may include medical services and higher worker’s
compensation premium. Indirect costs from increased employee turnover, absenteeism,
and retraining may also occur. Productivity, product quality and employee morale may
also suffer. Ultimately, ergonomics is used for industrial workstation to achieve an
appropriate balance between worker’s capabilities and work requirement to optimize
worker’s productivity and the total system as well as provide worker’s physical and
mental well-being, job satisfaction and safety (Fulter el al, 2000). The better technique
will be implementing to solve the problem.
1.3 Objective
a) To study and investigate the awkward posture that caused tiredness and back
pain to operators while do the task.
b) To analyze the workers working posture activities using RULA method.
c) To design and propose new solution.
d) To analyze the lighting and noise level at workplace.
3
1.4 Scope
The project mainly investigates the awkward posture that caused tiredness and back pain
to workers. At Jati Beringin Sdn. Bhd. the worker will do the assembling while sitting.
The location to improvement is assembling line. So, the project focuses to analyze
working posture and low back pain using RULA method. This project will analyze,
revise, and recommend a new technique as solution to improve present working posture.
1.5 Potential Benefits of Study
The potential benefits s from the study can be given to the following parties:
a) Factory employer
The project will be helping the factory to change the working environment especially
for the workers. For the project may increase productivity, reduced injuries, costly
downtime and comfortable working environment.
b) Factory workers
This project may help the worker to protect the health. The project may change the
workstation while the workers do the job and give the comfortable for workers.
Workers can avoid the body from tiredness and back pain.
c) Student
The project will increase knowledge on ergonomic based on real situation in
working area. Student can learned to use the analytical tools such as RULA tool to
implement the real life. Student also may help the company to increase productivity,
reduced injuries, costly downtime and comfortable working environment.
4
1.6 Structure of the Report
This report consist of introduction, theory, activities performed, suggestion and
modification of material handling method. Help to change the environment of
workstation. After that, reanalyze the result after doing the improvement. This report
consists five chapters. Each chapter is described as below:
a) Chapter 1
Chapter one is a introduction of the project, that consists the background of the
study, problem statement, objective project, scope of study, potential benefits of
study and structure of the report.
b) Chapter 2
Consists of the literature review about the theoretical concept of ergonomics.
Background study on the evolution of ergonomics science is shown. The relationship
between material handling activities and occupational health and types of safe
working posture also the illness and injuries involved in material handling are
started. Reviews are done on material handling which are suitable to be used for this
project.
c) Chapter 3
Are described details of the case studies that workers associated with manual
material handling activities. This chapter also consists of data analysis from
experiments and RULA results. The comparison on the effectiveness of current and
proposed working posture and the effects on the workers productivity also will be
briefly explained.
5
d) Chapter 4
Describe details about the effectiveness of implementation of RULA method. These
chapters also cover the noise assessment and lighting assessment.
e) Chapter 5
Is the final part of the project, which concludes the final year project. This
chapter will conclude the study objective and suggestion on future work.
6
CHAPTER 2
LITERATURE REVIEW
2.1 History of Ergonomics
(Christensen 1987) points out that the importance of a good fit between humans and
tools was probably realized early in the development of the species. Australopithecus
Prometheus selected pebble tools and made scoops from antelope bones in a clear
display of selecting objects to make tasks easier to accomplish. The association between
occupations and musculoskeletal injuries was documented centuries ago. (Bernardino
Ramazinni 1633-1714) wrote about work-related complaints that he saw in his medical
practice in the 1713 supplement to his 1700 publication, "De Morbis Artificum
(Diseases of Workers)."
In the early 1900's, energy human and ergonomic concept depend the largest of the
production industry that develop to improve worker productivity. Scientific
Management, is a method where to improved worker more efficiency by improving the
job process.
World War II encouraged greater interest in human-machine interaction as the efficiency
of sophisticated military equipment could be compromised by bad or confusing design.
Design concepts of fitting the machine to the size of the soldier and logical control
buttons evolved.
7
After World War II, the focus of concern expanded to include worker safety and
productivity. Research began in a variety of areas such as:
a) Muscle force required to perform manual tasks.
b) Compressive low back disk force when lifting.
c) Cardiovascular response when performing heavy labor.
d) Perceived maximum load that can be carried pushed or pulled.
Areas of knowledge that involved human behavior and attributes such as decision
making process, organization design, human perception relative to design became
known as cognitive ergonomics. The knowledge that involved physical aspects of the
workplace and human abilities such as force required to lift, vibration and reaches
became known as industrial ergonomics or ergonomics.
The broad groups focus and name duality continues at this time. Contributors to
ergonomics concepts include industrial engineers, industrial psychologists, occupational
medicine physicians, industrial hygienists, and safety engineers. Professions that use
ergonomics information include architects, occupational therapists, physical therapists,
occupational medicine nurses, and insurance loss control specialists. Figure 2.1 below
shows the method of ergonomic assessment.