PRODUCTION EFFICIENCY ENHANCEMENT USING IMPROVED WORKING POSTURE OF MATERIAL HANDLING ACTIVITY IN
FURNITURE INDUSTRY
NOOR FARAZDILLAH BINTI ISMAIL
FACULTY OF MANUFACTURING ENGINEERING UNIVERSITI TEKNIKAL MALAYSIA MELAKA
FAKULTI KEJURUTERAAN PEMBUATAN
Rujukan Kami (Our Ref) : 18 Mei 2009
Rujukan Tuan (Your Ref):
Pustakawan
Perpustakaan Universiti Teknikal Malaysia Melaka (UTeM) Taman Tasik Utama, Hang Tuah Jaya,
Ayer Keroh, 75450, Melaka
Saudara,
PENGKELASAN LAPORAN PSM SEBAGAI SULIT/TERHAD
- LAPORAN PSM SARJANA MUDA KEJURUTERAAN PEMBUATAN (PENGURUSAN PEMBUATAN): Noor Farazdillah Binti Ismail
TAJUK: Production Efficiency Enhancement Using Improved Working Posture of Material Handling Activity in Furniture Industry
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UNIVERSITI TEKNIKAL MALAYSIA MELAKA
BORANG PENGESAHAN STATUS LAPORAN PSM
JUDUL:
Production Efficiency Enhancement Using Improved Working Posture of Material
Handling Activity in Furniture Industry
SESI PENGAJIAN: Semester 2 (2008/2009)
Saya Noor Farazdillah Binti Ismail
mengaku membenarkan laporan PSM / tesis (Sarjana/Doktor Falsafah) ini disimpan di Perpustakaan Universiti Teknikal Malaysia Melaka (UTeM) dengan syarat-syarat
kegunaan seperti berikut:
1. Laporan PSM / tesis adalah hak milik Universiti Teknikal Malaysia Melaka dan
penulis.
2. Perpustakaan Universiti Teknikal Malaysia Melaka dibenarkan membuat salinan
untuk tujuan pengajian sahaja dengan izin penulis.
3. Perpustakaan dibenarkan membuat salinan laporan PSM / tesis ini sebagai bahan
pertukaran antara institusi pengajian tinggi.
4. *Sila tandakan (√)
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)
PRODUCTION EFFICIENCY ENHANCEMENT USING IMPROVED WORKING POSTURE OF MATERIAL HANDLING ACTIVITY IN
FURNITURE INDUSTRY
NOOR FARAZDILLAH BINTI ISMAIL
This report is submitted in partial fulfilment of the requirements for the Bachelor of Manufacturing Engineering (Manufacturing Management)
FACULTY OF MANUFACTURING ENGINEERING UNIVERSITI TEKNIKAL MALAYSIA MELAKA
DECLARATION
I hereby, declared this report entitled Production Efficiency Enhancement Using Improved Working Posture of Material Handling Activity in Furniture Industry is the
results my own research except as cited in references
Signature :………
Author’s Name :………
APPROVAL
This report is submitted to the Faculty of Manufacturing Engineering 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:
ABSTRACT
ABSTRAK
DEDICATION
I dedicate this project to my beloved parents, En. Haji Ismail B. Ahmad and Pn Hajah Siti Zabidah Binti Salleh, who offered me unconditional love and support throughout the
course of this final project. Without their patience, understanding, support and most of all love, the completion of this project would not have been possible.
For My PSM Supervisor:
ACKNOWLEDGEMENT
Utmost gratefulness to The Almighty Allah SWT for the abundant blessing and favours for me to accomplished the research in this Projek Sarjana Muda. The project had goes smoothly and had finished on the time given.
In addition to it, I would like to express my appreciation to my Supervisor, En AB Rahman Mahmood for all his priceless advices, help and support given to me from commencing of the Title Selection until the completion of my Projek Sarjana Muda. Thank you so much for all of the support and care.
TABLE OF CONTENTS
2.2 Introduction to Ergonomics 8
2.2.1 What are Musculoskeletal Disorders(MSDs)? 10
2.2.2 Workplace Factors Contribute to MSDs 12
(a)Visual Effort 14
2.2.2.2 Repetitive Motions 15
2.2.2.3 Force exertions 16
2.2.2.4 Vibration 16
2.2.2.5 Pressure Point 16
2.3 Defining Productivity and Efficiency 17
2.4 Effect of MSDs on Productivity Efficiency 17
2.4.1 Why are MSDs a Problem? 18
2.4.2 How do WMSDs affect productivity? 19
2.4.3 How can enhance productivity? 20
2.5 Safe working posture 21
2.5.1 Safe working posture in standing and sitting position for work surface height
22
2.5.2 Safe working posture in standing position 23
2.5.3 Safe working posture in sitting position 25
2.5.4 Safe working posture for lifting and carrying 26
2.6 Tools for safe working evaluation 28
2.6.1 Rapid Upper Limb Assessment (RULA) 28
2.7 Assessment research on material handling 30
3. RESEARCH METHODOLOGY 39
3.2.4 Tools 48
3.2.4.1 RULA 48
3.3 Procedure to evaluate the data 49
3.3.1 Steps using checklist 49
3.3.2 RULA analysis Procedures 50
3.3.3 Procedure of Experiment 53
4.2 Evaluation of Improvement 70
4.2.1 RULA analysis Revised Result 70
4.2.2 Productivity Result 76
4.2.2.1 Before Improvement 76
4.2.2.2 After Improvememnt 77
5. CONCLUSION AND RECOMMENDATION 81
5.1 Conclusion 81
5.1.1 To study the present material handling and investigate the awkward postures that caused tiredness and back pain to operators while performing their tasks
81
5.1.2 To analyze the workers’ posture and lifting limits on material handling activities using checklist and RULA, then the finding will be evaluate using experimental method.
82
5.1.3 To propose a new and efficient technique of materials
handling for Hasro’s workers
82
5.2 Recommendation 83
REFERENCES 85
APPENDICES
A Posture Checklist B Scissor lifter Drawing
C Reference Diagram for RULA Analysis
LIST OF TABLES
2.1 Summaries of articles, journals, and researches 30
3.1 Gantt chart for PSM I 41
3.2 Gantt chart for PSM II 42
3.3 Example of variable table used. 46
4.1 Angle of body part deviate from neutral position 57
4.2 Posture risk assessment for Group A 58
4.3 Posture risk assessment for Group B 59
4.4 Scoring for Group A body part 59
4.5 Scoring for Group B body part 60
4.6 Grand Score 60
4.7 Angle of body part deviate from neutral position 60
4.8 Posture risk assessment for Group A 62
4.9 Posture risk assessment for Group B 62
4.10 Scoring for Group A body part 63
4.11 Scoring for Group B body part 63
4.12 Grand Score 63
4.13 Angle of body part deviate from neutral position 64
4.14 Posture risk assessment for Group A 65
4.15 Posture risk assessment for Group B 65
4.16 Scoring for Group A body part 66
4.17 Scoring for Group B body part 66
4.18 Grand Score 66
4.19 Angle of body part deviate from neutral position 67
4.21 Posture risk assessment for Group B 69
4.22 Scoring for Group A body part 69
4.23 Scoring for Group B body part 69
4.24 Grand Score 70
4.25 Angle of body part deviate from neutral position 71
4.26 Posture risk assessment for Group A 72
4.27 Posture risk assessment for Group B 72
4.28 Scoring for Group A body part 73
4.29 Scoring for Group B body part 73
4.30 Grand Score 73
4.31 Table of product produced before improvement 77
LIST OF FIGURES
2.1 Example of awkward posture 13
2.2 Repetitive work 15
2.3 Percent of total Lost-Time Injuries by type of occupational injuries and illnesses
18
2.4 Percent of total WSIB costs by type of occupational injuries and illnesses
19
2.5 .
Ergonomics Job Consideration
22
2.6 A workstation designed for a standing and sitting worker 23 2.7 Workplace which has enough space to change working
position
24
2.8 A worker's leg on a foot rail or portable foot-rest. 24
2.9 Safe working sitting posture. 26
2.10 Lifting and carrying the box with safe working posture 27 2.11 Lifting and carrying the stone with safe working posture 28
2.12 The RULA methods scoring sheets 30
3.1 Flow chart for planning of study 43
3.2 Illustration of Ergoweb software 51
3.3 An example of biomechanical model 51
3.4 Selection of RULA in the job evaluator toolbox 4.0 51 3.5 Posture Risk Factor Assessment for Group A (upper arm,
lower arm, and wrist)
52
3.6 Posture Risk Factor Assessment for Group B (neck, trunk, and legs)
4.1 The worker bending to lift the material 42
4.2 The worker bending to lift the material 61
4.3 The worker bending to lift the material 64
4.4 The worker bending to lift the material 67
4.5 The worker bending to lift the material 71
4.6 Graph of the Effective action level of RULA. 74
4.7 Side view for the proposed improve lifting task 75
4.8 Top view for the proposed improve lifting task 76
CHAPTER 1
INTRODUCTION
This chapter explains the background of the study which consist the study background, problem statements, objectives, scope and limitation of project.
1.1 Background of study
The study is about production efficiency enhancement using improved working posture of material handling activity in a furniture industry. The study is conducted to identify posture that caused tiredness and back pain to operators while performing their tasks through survey and observation. Then, from the data collected, the analysis will be done to determine the problems on material handling activity. The improvement proposed by using the engineering control to reduce the injuries risk faced by HASRO‘s workers.
1.1.1 The significant of project
The important of this project are:
(a) To know whether the current working posture is safe or not. (b) To identify the factors that causing the tiredness and back pain.
1.1.2 Company background
Hasro Furniture Gallery (M) Sdn. Bhd. which is s located at Lot 12, Jalan PBR 28, Phase 4C, Bukit Rambai Industrial Area, 75250 Melaka. Hasro was established in 1978 as an enterprising cottage industry that sought to create unique and quality furniture for a discerning market. The founder, Mr. Hashim Mohamad is the successor of a family with long established wood carpentry tradition and was responsible in moulding the commercial entity out of his lifelong passion for woodworking and craftsmanship. Through its growth, Hasro has made a name for itself in being totally committed to achieving the highest standards of furniture making. Today, Hasro‘s product has successfully gained international market appeal with demands growing beyond Malaysian shores.
1.2 Problem statement
mental well-being, job satisfaction and safety (Fulter el al, 2000 ). The better technique will be recommended as a solution to overcome these problems.
1.3 Objectives
(a) To study the present material handling and investigate the awkward postures that caused tiredness and back pain to operators while performing their tasks.
(b) To analyze the workers‘ working posture and lifting limits on material handling activities using checklist and RULA, then the finding will be evaluate using experimental method.
(c) To propose a new and efficient technique of materials handling for Hasro‘s workers
1.4 Scope and Limitation
1.5 Potential Benefits of Study
The potential benefits from this study can be given to the following parties:
(a) Factory employer
This study may help the factory employer to improve the working environment for the workers, which also decrease the possibility of workers absent due to occupational health problems, and this will improve the workers‘ productivity.
(b) Factory workers
This study may help workers more alert about the risk of having occupational health problems. Besides that, workers‘ discomfort will be reduced if the proposed solution is implemented.
(c) Student
This report consists of introduction, theory, activities performed, recommendation and modification of material handling method, and reanalyze the results after doing improvements. The report consists of five chapters and each chapter is described as below:
Chapter 1, the background study of the project, a brief introduction of the selected
manufacturing factory, problem statement, objectives of the project, scope of study, potential benefits of study and the report structure is included as well.
Chapter 2 consists of the literature review about the theoretical concept of ergonomics
and the connection with material handling. Background study on the evolution of ergonomics science is shown. The relationship between material handling activities and occupational health and types of safe working postures also the illness and injuries involved in material handling are stated. Tools for safe working evaluation are also included. Reviews are done on material handling which are suitable to be used for this project.
Chapter 3 is provides the information and method used in order to achieve the objectives
of the project. Briefly description about the procedures and method such as determination of workers‘ responses regarding the discomfort in the manufacturing factory, observation tools and methods and solutions to improve the current material handling methods.
Chapters 4 are described details of the case studies that workers associated with manual
materials handling (MMH) 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 worker‘s productivity also will be briefly explained.
Chapter 5 is the final part of the project, which concludes the Final Year Project. This
CHAPTER 2
LITERATURE REVIEW
In this chapter, it is containing information which related to this study. It is also covers introduction to ergonomics and awkward posture, methods and tools for posture that been used in previous studies.
2.1 Ergonomics Overview
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/creating objects to make tasks easier to accomplish. The relationship between the factors of human occupational injuries and engineering of work tools is found to have been documented long time ago. It proves that work in the field of ergonomics had been started 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)‖.
