UNIVERSITI TEKNIKAL MALAYSIA MELAKA
HUMAN ACTIVITY ANALYSIS USING DELMIA
ERGONOMICS IN JTKP MACHINING TECHNOLOGY
LABORATORY (LATHE)
This report is submitted in accordance with the requirement of Universiti Teknikal Malaysia Melaka (UTeM) for the Bachelor of Manufacturing Engineering
Technology (Product Design) with Honours
by
TAN JIA ZHEN B071210071 920611-01-5060
DECLARATION
I hereby, declare that this thesis entitled “Human Activity Analysis using DELMIA Ergonomics in JTKP Machining Technology Laboratory (Lathe)” is the result of my
own research except as cited in references.
Signature : ………
Name : ………
APPROVAL
This report is submitted to the Faculty of Engineering Technology of UTeM as one of the requirements for the award of Bachelor of Manufacturing Engineering Technology (Product Design) with Honours. The member of the supervisory is as
follow:
i
ABSTRAK
ii
ABSTRACT
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DEDICATION
iv
ACKNOWLEDGEMENT
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LIST OF ABBREVATIONS, SYMBOLS AND NOMENCLATURES ... xiii
CHAPTER 1: INTRODUCTION ...1
1.1 Background ...1
1.2 Problem Statement ...2
1.3 Objectives...3
1.4 Scope of the study ...3
CHAPTER 2: LITERATURE REVIEW ...4
2.1 Introduction ...4
2.2 Workplace Evaluation...4
2.2.1 Working Postures ...4
2.2.2 Working Layout...6
2.2.3 Musculoskeletal Disorders (MSD) ...8
2.3 Ergonomics in the Lathe Laboratory ...10
2.3.1 Lathe Machine ...12
2.4 Methods for Ergonomics Assessment...14
2.4.1 RULA (Rapid Upper Limb Assessment) ...14
2.4.2 REBA (Rapid Entire Body Assessment) ...18
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2.5 DELMIA Ergonomics based on CATIA Version 6 (V6) ...26
CHAPTER 3: METHODOLOGY ...29
3.1 Identifying the Study Problem ...30
3.2 Library Research ...30
3.3 Identification of Human Activity ...30
3.4 Human Activity Analysis...32
3.5 Data and Result Analysis ...35
3.6 Report Writing and Compilation ...35
CHAPTER 4: RESULT AND DISCUSSION ...36
4.1 Simulation Machine Layout and Manikin Edition...37
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4.5.2 Male Manikin ...72
CHAPTER 5: CONCLUSION ...75
5.1 Conclusion ...75
5.2 Recommendation for Future Work ...76
APPENDIX A ...77
APPENDIX B...78
APPENDIX C ...79
APPENDIX D ...81
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LIST OF TABLES
Table 2.1: The categorization of risk level under RULA...17 Table 2.2: The categorization of risk level under REBA. ...17 Table 2.3: The standardization of the categorization of RULA and REBA methods. .21 Table 2.4: Distribution of sampled postures. ...24 Table 2.5: Distribution of action category/level for 301 postures by three methods. ..24 Table 2.6: Coincidence rate of evaluation results between the three methods (%). ....25 Table 4.1: The anthropometric data of 6 respondents (Three male and three female).36 Table 4.2: The scores of the Level of MSD Risk by RULA analysis tool...57 Table 4.3: RULA score for the upper arm of six respondents on both sides of body to move the carriage table toward x-axis and z-axis. ...58 Table 4.4: RULA score for the forearm of six respondents on both sides of body to move the carriage table toward x-axis and z-axis. ...59 Table 4.5: RULA score for the wrist of six respondents on both sides of body to move the machining table toward x-axis and z-axis. ...61 Table 4.6: RULA score for the neck and the trunk of six respondents to move the carriage table toward x-axis and z-axis. ...62 Table 4.7: The scoring for final score of RULA analysis in Table C of RULA
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LIST OF FIGURES
Figure 2.1: The risk factors of awkward working postures Source: Safety in
Manufacturing, 2000]. ...5 Figure 2.2: Descriptions of Neutral Postures Midpoints for the Body Joints [Source: Ergonomics, 2009]. ...6 Figure 2.3: Horizontal and vertical reach zones of a worker in a workstation [Source: Lista making workspace work, 2012]. ...7 Figure 2.4: Musculoskeletal disorders (MSDs) affected body parts [Source: Spine Place: Empowering Ordinary People with Extraordinary Health, 2014]...9 Figure 2.5: Conceptual model of the relationship between trunk postures and Lower Back Pain [Source: Nico J. D., 2004]. ...11 Figure 2.6: The basic components part of a lathe machine [Source: Terminology, 2013]...12 Figure 2.7: The standard lathe machine coordinate system [Source: Positioning, 2015]...13 Figure 2.8: Scores of the level of Musculoskeletal Disorders (MSDs) risk by RULA [Source: Ergonomics Plus, (n.d.). A Step-by-Step Guide to the RULA Assessment Tool] ...14 Figure 2.9: Snapshots from video on the workers body postures while doing their jobs [Source: Ansari N. A., 2014]. ...15 Figure 2.10: The RULA score according to position of body parts by using
ErgointeligenceTM software [Source: Ansari N. A., 2014]. ...16
Figure 2.11: The REBA score according to position of body parts by using
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Figure 2.15: Comparison of the postural analysis results: RULA and REBA [Source: Fernanda D.de.S., 2006]. ...21 Figure 2.16: Posture classification and codes for different body parts of OWAS system [Source: Waldemar K., 2003]. ...23 Figure 2.17: Percentage distribution of action category/level for 301 postures by three methods [Source: Kee D., 2007] ...25 Figure 2.18: DELMIA Ergonomics Analysis (EGA) analyze and predict human safety, comfort and performance directly within the 3D virtual environment [Source: DELMIA, 2002]. ...26 Figure 2.19: The human model interaction with arm strength gymnastic device in CATIA V6 software [Source: Ye Z. H., 2013]. ...28 Figure 3.1: Process flow chart of Bachelor Degree Project. ...29 Figure 3.2: Observation of students while using lathe machine in Machining
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LIST OF ABBREVATIONS, SYMBOLS AND
NOMENCLATURES
BDP - Bachelor Degree Project
CATIA V6 - CATIA Version 6
EGA - DELMIA Ergonomics Analysis
EGE - DELMIA Ergonomics Evaluation
FTK - Faculty of Engineering Technology
HAA - Human Action Analysis
HBR - Human Builder
HME - Human Measurement Edit
HPA - Human Posture Analysis
LBP - Lower Back Pain
MSD - Musculoskeletal Disorders
NIOSH - National Institute for Occupational Safety and
Health
OWAS - Ovako Working Postures Assessment System
REBA - Rapid Entire Body Assessment
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CHAP TER 1
INTRODUCTION
1.1 Background
First of all, ergonomics is the study of human in the working environment. Ergonomics also concerned with the comfort, health and safety, and productivity. Nowadays, ergonomics is very important in any subject of field because it provides us a way to analyze our body postures when our body is under any ergonomics risk factors. All of this risk factors will contribute to Musculoskeletal disorders (MSD) are the disorders where the human body gets traumatized over a period of time. Many industry always overpass these types of disorders where it tend to cause the sickness slowly appeared within the workers body. In fact, this problem can be foreseeable when time passed by. Therefore, ergonomic analysis should be done to overcome this kind of diseases so that everyone has a healthy and comfort posture when doing their job every time.
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actions while processing the lathe machine. Vertical and horizontal reaches of upper parts of body as well as position of visual display was taken in consideration too.
The approach that was used to perform the human activity analysis is by using the DASSAULT SYSTEMES software, CATIA V6. This software allows users to do the DELMIA Ergonomics analysis. A 3D virtual environment and lifelike manikins can be created to perform the working tasks. Users can analyze and predict the comfort or safety scoring of the working postures by observing color coding of Rapid Upper Limb Assessment (RULA) analysis. RULA is a method for analyzing risk factors to the upper limb of the user-defined manikin or human in an actual physical environment. The RULA analysis can measures several risk factors such as body movements, static work load, force, working posture and time worked without a break.
1.2 Problem Statement
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1.3 Objectives
The main objectives in this project are:
i. To study and simulate several human’s task related to human capabilities while using lathe machine in JTKP Machining Technology Laboratory. ii. To identify and propose the ideal working posture while working on lathe
machine to minimize the risk from suffer MSD.
iii. To identify relevant collected anthropometric dimensions in human-machine interaction that could be related to awkward working postures.
1.4 Scope of the study
The scope on this project covers on:
i. Using DELMIA V6 Ergonomics software to study and simulate human activity.
ii. Observe and analyze the laboratory work on lathe machine.
iii. Rapid Upper Limb Assessment (RULA) ergonomics analysis will be used based on recommendations from National Institute for Occupational Safety and Health (NIOSH).
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CHAP TER 2
LITERATURE REVIEW
2.1 Introduction
For further process of this research project, literature review makes an important key of it. The sources of literature survey are obtained from the books, journals and also electronic resources. All of the information was based on the past studies related to ergonomics fields. Therefore, it had covers on the study of workplace evaluation, ergonomics in the lathe laboratory, ergonomics assessment tools and DELMIA Ergonomics based on CATIA V6.
2.2 Workplace Evaluation
2.2.1 Working Postures
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Figure 2.1: The risk factors of awkward working postures Source: Safety in Manufacturing, 2000].
Awkward working postures are caused by the joints position of body that is not moving in neutral range of postures. Movement of joints such as bending the neck forward more than 30 degrees, raising the elbow above the shoulder, bending the back forward greater than 45 degrees and squatting will lead to extreme awkward postures. To avoid awkward working postures, the joints of body should maintain in a neutral range of postures. Postures within the neutral range can contribute in high force production or control of body and reduce the stress apply on the tissues, muscle, nerves and bones. Figure 2.2 showed the descriptions of neutral postures midpoints
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Figure 2.2: Descriptions of Neutral Postures Midpoints for the Body Joints [Source: Ergonomics, 2009].
2.2.2 Working Layout
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There were many guidelines and principles in the design of workstation. One of it was apply the anthropometric data to workspace design. This mean the dimension for workstation design is determine according to the anthropometric data while doing industrial tasks such as reaching, sitting, standing and sit-stand positions. The populations for male and female workers consist of 5th, 50th and 95th percentiles
based on the existing anthropometric data. The design of reaching limits and clearance requirements were based on the smaller (5th percentile) and larger (95th
percentile) dimensions of individual worker. The zones for reaching and clearance were shown in Figure 2.3.
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Besides that, to solve the workstation design problems, Ernest J. McCormick had stated out four principles of rational workspace layout, which are [5]:
Importance principle: The most important items should be in the most accessible locations.
Frequency of use principle: The most frequently used items should be in the most accessible locations.
Function principle: Items with similar functions should be grouped together. Sequence of use principle: Items that are commonly used in sequence should be
laid out in the same sequence.
2.2.3 Musculoskeletal Disorders (MSD)
