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.

vii

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.