Analysis Of Working Posture Of Operator In Mixing Department Of An SMI In Malaysia.

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UNIVERSITI TEKNIKAL MALAYSIA MELAKA

Analysis of Working Postures of Operator in

Mixing Department of an SMI in Malaysia

Thesis submitted in accordance with the requirements of the Malaysia Technical University of Malacca for the Degree of Bachelor of Engineering Manufacturing

(Process)

By

Saidah binti Khalid

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DECLARATION

I hereby declare this thesis entitled “Analysis of Working Postures of Operator in Mixing Department of an SMI in Malaysia” is the results of my own research

except as cited in the references.

Signature : ………...

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APPROVAL

This thesis submitted to the senate of UTeM has been accepted as fulfillment of the requirement for the degree of Bachelor of Engineering

Manufacturing (Process). The members of the supervisory committee are as follows:

………. Main supervisor

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ABSTRAK

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ABSTRACT

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ACKNOWLEDGEMENT

In the name of Allah, Most Gracious, Most Merciful.

All praise to the Almighty Allah for giving me the strength, patience and guidance throughout the process of completing this Projek Sarjana Muda (PSM). I am grateful to have the support and motivation from a lot of people in accomplish this research. I would like to take this opportunity to thank those who are either directly or indirectly involve during this research is conducted.

Mostly a special gratitude goes to my respective supervisor, Prof.Madya Dr. Adi Saptari from Faculty of Manufacturing Engineering. Thank you so much for the precious time, advices, contributions, comments and guidance in every stage of this research.

My token appreciation also goes to my beloved family members who never failed to be there for their love, support and prayers. Last but not least, I would like to thank to all my friends, especially my classmates and housemates for the never ending supports.

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DEDICATION

To all my siblings;

For your love, encouragement, and support on this project was absolutely

invaluable.

To my respectful Supervisor;

Prof Madya Dr. Adi Saptari

For your guidance and help in completing this project. You are always in my mind.

To my special partner;

Syahrul Affendi bin Ismail

For all your support and motivation during the completion of this research

Especially to my father

Khalid bin Tomi

And the memory of my late mother

Manisah bt Suratman

For your support, love and demonstration of the values of education since I’m still

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LIST OF ABBREVIATIONS

PSM = Projek Sarjana Muda

PERKESO = Social Security organizational of Malaysia RWL = Recommended Weight Limit

LI Lifting Index

RULA = Rapid Upper Limit Assessment REBA Rapid Entire Body Assessment MSD = Musculoskeletal Disorders CTD = Cumulative Trauma Disorder CAD Computer Aided Design

NIOSH National Institute for Occupational Safety and Health SMI Small Medium Industry

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LIST OF TABLES

2.1 Various methodologies used in previous study 33

4.1 Anthropometry data of the subjects 45

4.2 Magnitudes of every subject for different sub process 48

4.3 Description of RULA action level 49

4.4 RULA score or standing position 50

4.5 RULA score for untie position 51

4.6 RULA score for lifting position 53

4.7 RULA score for unloading position 54

4.8 REBA action level 57

4.9 Summary of results for REBA analysis 58

4.10 Definition of Components of NIOSH Lifting Equation 63 4.11 Frequency Multiplier (FM) (Note: 75cm = 30 inches) 64

4.12 Coupling Multiplier 64

4.13 Results for the value of RWL and LI for different heights 71 5.1 Results of RULA, REBA analysis and the 1991 NIOSH 73

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LIST OF FIGURE

1.1 Statistic of Accidents Reported to Perkeso from 1999 to 2004 3 1.2 Number of Accidents by Cause of Accidents 2004 4 1.3 Number of Accidents by Location of Injury 2004 4

1.4 Number of Accidents of the Upper Limb 2004 5

1.5 Number of Accidents of the Trunk 2004 5

2.1 Kind of Accident causing over three-day-injury, 2001/02 10

2.2 Vertebral column 14

2.3 Division of the Skeleton 15

2.4 Typical lumbar vertebrae 17

2.5 Division of the Upper Extremity 18

2.5 Low-back biomechanical model of static coplanar lifting 20

3.1 Methodology of project 35

4.1 The workers is unloading the material to the funnel 42 4.2: Image of an operator pulling the sack from the pallet. 43 4.3 Two lines were constructed to determine upper arm and forearm angles. 44 4.4 A manikin that created using the anthropometry data measured 45 4.5 The worker pulling the sack from the pallet 46

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4.12 The required distance of the workstation that is measured 65

4.13 Recommended vertical lifting height 71

5.1 Figure of the tilt table 75

5.2 The application of the tilt table 75

5.3 The result of RULA analysis 76

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CHAPTER 1 INTRODUCTION

1.1 BACKGROUND OF STUDY

Lifting is done every day no matter in working neither condition nor the usual activity that we do everyday. We need to lift something in order to move it to the desired place. While performing the activities, people managed to get injured internally or externally. This study is done to identify the types of injury that usually happens during lifting. In this chapter, the reader will be introduced with the problem and the theoretical background. The objective and scope of the project also is also stated here.

Injury is one of the problems that always happened to human being. Injury can be defined as hurt, pain, and suffering. Usually injury is realized automatically when we hurt by something that sharp such as knife or when involved in accidents. But the injury that happened in the body system such as the skeletal system, muscle and joints is not noticed until the person faced serious problem such as back pain and injury to the muscle. One of the factors that contribute to this problem is picking task.

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This activity can lead to back pain problem and CTDs (upper-extremity cumulative trauma disorders).

Social Organizational Security of Malaysia (PERKESO) is an organization that is committed to ensure socio-economic security of all working Malaysian citizens including their dependants. Most of the workers in Malaysia are registered with PERKESO that will cover them if they experienced any injury during the duration of working. From the statistic by PERKESO for the year 2004, they are about 10,238,554 registered workers but only 4,567,365 are active workers. From the statistic, they are about 69,132 registered accidents with 9,381 cases of permanent disable and 846 of death cases. This means that there are many cases of injury that are not reported to PERKESO.

From the statistics, industrial sector gives the biggest number of accidents which are 26,690 cases. This numbers shows that the workers in the industry face the highest risk of injury compare to other sectors. In Figure 1.1, the histogram shows the statistic of injury from year 1999 to 2004. The statistic shows that number of accidents decrease every year. According to Figure 1.2, the accidents are divided to the causes of accidents. The causes of accidents are falling, crushed by falling objects, crushed by object (except falling objects), stuck in an object or between two objects, exposed to hot or cold environment, exposed to electric current and chemicals, heavy movements and others. One of the causes of accidents is heavy movements which divided into four categories; injury when lifting objects (591 cases), injury when pulling and pushing objects (268 cases), injury when managing objects (287 cases), and heavy movements (289 cases). Heavy movement is one of the factors of accidents that frequently happened in the industrial sector especially in the production line where these activities are practiced everyday.

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35253 cases of upper limb, 8186 cases of multiple locations, 16818 cases of the lower limb and 683 cases of general injuries. From the statistic, the most frequent injury happened are at the upper limb which included the shoulder, upper arm, elbow, forearm, wrist, hand, fingers, and upper limb. The statistics shows the number of pain for the upper limb where the locations that give higher reading are shoulder (2,260 cases), wrist (1,009 cases), hand (8,678 cases) and fingers (16,560 cases).

Figure 1.5 shows the number of accidents for the trunk. The locations are divided into back, abdomen, chest, pelvis, trunk and multiple locations and unspecified locations. The highest number of injury of the trunk happened at the back estimated 1,463 cases. From the statistics, it shows that the workers who involve in the material handling and lifting task activities especially at the production line have the highest possibilities to experienced injury especially the lower back pain and MSDs for upper extremity. It is very important for them to know their rights as the workers so that they could learn to prevent the injury in the warehouse. This analysis is conducted in order to find the types of injury they could experienced and what are the preventive actions can be conducted.

Statistic of Accidents Reported to Perkeso

92,07495,006

1999 2000 2001 2002 2003 2004

Year

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Number of Accidents by Caused of Accidents 2004 Stuck in an Object or Between Two Objects

Source: Statistics taken from http://www.perkeso.gov.my/statistikpage1.htm

Number of Accidents by Location of Injury 2004

16818, 24%

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Number of Accidents of the Upper Limb 2004 Source: Statistics taken from http://www.perkeso.gov.my/statistikpage1.htm

Number of Accidents of the Trunk 2004

1,463, 33%

TRUNK, MULTIPLE LOCATIONS TRUNK, UNSPECIFIED LOCATION

Figure 1.5: Number of Accidents of the Trunk 2004

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1.2 PROBLEM STATEMENT

From the statistics produced by Social Organizational Safety Malaysia (PERKESO), industrial sector gives the biggest number of accidents which are 26,690 cases from 69,132 cases. In 2004 there are about 58247 cases of injury from 4,567,365 active workers is related to lifting task activities resulted of overexertion or repetitive motion. Most of the cases affected the back and the pain on the upper extremity of the body such as shoulder, neck, hand, and wrist. Generally, this entire problem occurred along the warehouse workers as they involved directly to the repetitive lifting task activity.

Repetitive tasks, especially if forceful, can temporarily make many musculoskeletal disorders more painful. (Davis T.R.C., 1999). Repetitive task that involving heavy loads contributes to the developing of back pain and CTDs (Cumulative Trauma Disorders). CTDs develop overtime due to repetitive stress applied to a joint, typically the upper extremities. (Gangopadyay S. et al, 2003).

Generally, human only can lift an object as long as they have enough energy to support the load. The energy needs to lift the object depends on the weight of the object. The heavier the object, the more energy needed. Human energy will count on the biomechanics of work and it relate to human physical body capability. Other than weight, the frequency of lifting also affects human body. Performing lifting task repetitively will also affect the human physical body. This is lifting frequency has a relationship with the duration of work. Naturally, human will get tired out after sometimes.

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1.3 OBJECTIVES

The objectives of the study are:

• To identify the causes of injury may happen during lifting an object. • To analyze working postures due to lifting activities.

• To provide suggestions on how to improve workstation in order to reduce back pain and CTDs.

1.4 SCOPE

The scope of the project is to find the types of injury that usually occurs during the lifting activity in manufacturing warehouse. In industry, the workers still do not aware of the long term effect because of the picking task activity that is done repetitively and not following the RWL (recommendation work limit).

The study will be carried along the mixer department operator at an SMIs (Small Medium Industry) company as they involved in the repetitive picking task of heavy loads everyday. The study is carried out in a company producing plastic products such as rain gutter system, pipes and fittings, and cable slab. The company is located at Kuala Selangor.

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CHAPTER 2 LITERATURE REVIEW

2.1 MANUAL MATERIAL HANDLING

More than a third of all over-three-day injuries reported each year to HSE and local authorities are caused by manual handling - the transporting or supporting of loads by hand or by bodily force. The pie chart shows the pattern for over-three-day injuries reported in 2001/02. The most recent survey of self-reported work-related illness estimated that in 2001/02, 1.1 million people in Great Britain suffered from musculoskeletal disorders (MSDs) caused or made worse by their current or past work. An estimated 12.3 million working days were lost due to these work-related MSDs. On average each sufferer took about 20 days off in that 12-month period. Figure 2.1 shows the kind of accident causing over three-day-injury in the year 2001/02. (Health and Safety Executive, 2006)

Manual handling injuries can occur wherever people are at work - on farms and building sites, in factories, offices, warehouses, hospitals, banks, laboratories, and while making deliveries. Heavy manual labour, awkward postures, manual materials handling, and previous or existing injury are all risk factors implicated in the development of MSDs.

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Figure 2.1: Kind of Accident causing over three-day-injury, 2001/02

(Source: Health and Safety Executive (2006) Getting to Grip with Manual Handling: A Short Guide (2006) INDG143(rev2))

The word lift means raise up, pick up or take up. Lifting something up means lift, take up, gather up or snatch up. For this study, picking task is referred to lift or pick some amount of an object to move or store them in the required position. This activity usually practiced in the in the production department in the manufacturing company. The materials usually are solids that come as bags, boxes or containers with or without handle. There are many ways to pick an object but usually the workers practiced wrong techniques to lift or pick an object.

Picking or lifting is defined as moving or bringing something from a lower level to a higher one. The concept encompasses stresses resulting from work done in transferring objects from one plane to another as well as the effects of varying techniques of patient handling and transfer. Forceful movements include movement of objects in other ways, such as pulling, pushing, or other efforts.

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physical work and awkward postures). Some studies had definitions for lifting which include criteria for number of lifts per day or average amount of weight lifted (Bernard

et al, 1997).

According to Kroemer et al, 2001, while doing lifting activity, our body will strained as we have to bend, stretch, move or strengthen our body parts. Usually the body parts that involved during picking task are the back, shoulder, hand, and wrist. Heavy loads pose an additional strain on the body, owing to their mass or bulk or their lack of handles.

The back is directly involved while picking and the part that affected is the disc of the lumbar spine. Kroemer et al, 2001 suggested that when one considered all the musculoskeletal structures within the trunk, a variety of elements may be strained, either singly or combined, including the spinal vertebrae (primarily their disc or facet joints), but also connective tissues such as ligaments and cartilage, as well as their muscle with their tendons.

2.2 THE SKELETAL SYSTEM

The Skeletal System serves many important functions; it provides the shape and form for our bodies in addition to supporting, protecting, allowing bodily movement, producing blood for the body, and storing minerals. The skeletal system consists of the bones, connectives tissues, joints, spinal column and the muscle.