UNIVERSITI TEKNIKAL MALAYSIA MELAKA
NOISE EXPOSURE LEVEL MONITORING IN A FURNITURE
INDUSTRY
Thesis submitted in accordance with the requirements of Universiti Teknikal
Malaysia Melaka for the Bachelor Degree of Manufacturing Engineering in
Manufacturing Management
By
MOHD IKHWAN BIN ISHAK
Faculty of Manufacturing Engineering
UTeM Library (Pind.1/2007)
UNIVERSITI TEKNIKAL MALAYSIA MELAKA
BORANG PENGESAHAN STATUS TESIS*
JUDUL: Noise Exposure Level Monit oring in a Furnit ure Indust ry
SESI PENGAJIAN: 2007/ 2008
Saya : MOHD IKHWAN BIN ISHAK
mengaku membenarkan t esis (PSM/ Sarj ana/ Dokt or Falsaf ah) ini disimpan di Perpust akaan Universit i Teknikal Malaysia Melaka (UTeM) dengan syarat -syarat kegunaan sepert i berikut :
1. Proj ek adal ah hak milik Universit i Teknikal Malaysia Melaka .
2. Perpust akaan Universit i Teknikal Malaysia Melaka dibenarkan membuat salinan unt uk t uj uan pengaj ian sahaj a.
3. Perpust akaan dibenarkan membuat salinan proj ek ini sebagai bahan pert ukaran ant ara inst it usi pengaj ian t inggi.
4. **Sila t andakan (√)
SULIT
TERHAD
√ TIDAK TERHAD
(Mengandungi maklumat yang berdarj ah keselamat an at au kepent ingan Mal aysia yang t ermakt ub di dalam AKTA RAHSIA RASMI 1972)
(Mengandungi maklumat TERHAD yang t elah dit ent ukan oleh organisasi/ badan di mana penyelidikan dij alankan)
(TANDATANGAN PENULIS)
Alamat Tet ap:
No 203, Jalan Wawasan 13, Taman Wawasan, 86800 Mersing, Johor.
APPROVAL
This PSM submitted to the senate of Universiti Teknikal Malaysia Melaka (UTeM) and has been
as partial fulfillment of the requirements for the degree of Bachelor of Manufacturing
Engineering (Manufacturing Management). The member of the supervisory committee is:
………
PUAN ROHANA BINTI ABDULLAH
Project Supervisor
Faculty of Manufacturing Engineering
DECLARATION
I hereby, declared this thesis entitled “Noise Exposure Level Monitoring in a Furniture Industry”
is the result of my own research except as cited in references.
Signature : ………...
Author’s Name : Mohd Ikhwan Bin Ishak
ACKNOWLEDGEMENTS
Bismillahirrahmanirrahim…
Praise to Allah Almighty for giving me a chance to complete my PSM. First at all, I would like
to thank my beloved parents, Mr. Ishak Bin Mohammad and Mdm. Sariah Binti Ismail for their
full support and always be there for me in giving ideas. I would also like to thank all UTeM
lecturers and staffs especially to my PSM Supervisor, Mdm. Rohana Binti Abdullah and my
PSM panel, Mr. Nik Ahmad Farid Bin Che Zainal Abidin.
In addition, I would like to state my extremely contribution to all Teknion Furniture System
(Malaysia) Sdn. Bhd. staff, especially to the Maintenance Manager, Mr. Azri Bin Munani, as a
person who supervise me for my research and others whom their name not been stated. I would
like to give a lot of thanks for their support, and assist in terms of their knowledge and
information that help me a lot during my research in Teknion Furniture System (Malaysia).
Last but not least, my special thanks to all of my colleagues that always giving assist for me to
finish this research. Without all of you, I would not be where I’m today. Thank you again.
Wassalam…
DEDICATION
For my adored parents:
Ishak Bin Mohammed
Sariah Binti Ismail
And for my respected brother and sisters:
Mohd Ikmal Bin Ishak
Mohd Ihsan Bin Ishak
ABSTRACT
This research is about the noise level monitoring in a furniture industry. Noise can be
defined as unwanted sound which is very loud and irritating to out ears. This research begins
with literature review taken from journals, books, articles, dictionaries, websites, electronic data
bases and also previous study done. All of these resources will help to provide information
about the previous study and give a clear view to determine the problem statement, objectives
and scope of the study. In the methodology chapter, the general idea of the research flow will be
explained. This research began with identifying the problem statement which includes the
objectives and scope of the research. After that, literature review is done in order to gather
information and determines the best step to complete the research. Data collections will be done
using observations and measuring devices. All data gain in the data collection process will be
analyzed using statistical method and measurement devices software. The final step is to propose
recommendations and suggestions to help the company improve in the working area for their
workers.
ABSTRAK
Kajian ini membincangkan tentang pemantauan bunyi bising di dalam bidang industri
perabot. Bunyi bising boleh ditafsirkan sebagai bunyi yang terlalu kuat dan menyakitkan telinga.
Kajian ini bermula dengan ulasan karya dari artikel-artikel, buku, jurnal, kamus, laman web,
pengkalan data elektronik dan kajian sebelumnya. Semua sumber ini digunakan untuk
mengumpul informasi terhadap kajian lepas dan memberi penjelasan terhadap pernyataan
masalah, objektif dan skop kajian. Pengumpulan data dilakukan mengunakan kaedah soalan kaji
seledik dan alat pengukuran. Data yang dikumpul akan di analisa mengunakan kaedah statistik
dan perisian alat pengukuran. Langkah terakhir adalah mencadangkan langkah untuk
memperbaiki keadaan syarikat berdasarkan konsep ergonomik.
TABLE OF CONTENTS
List of Abbreviations, Symbols, Specialized Nomenclature………...x
1.0 INTRODUCTION………...1
1.1Introduction………...……….………1
1.2Statement of Problem……...…..……….……….3
1.3 Objectives………..………...………….……3
2.3 Ergonomics and Environmental….………...………...9
2.4 Environmental Issues………...11
2.4.1 Noise Level……...……….………...11
2.5 The Effect of Environmental Issues………….………..14
2.6 Equipment..…………..……….……….15
2.6.1 Extech Digital Sound Level Meter Model 407730………….……….…….15
2.7 Noise Level Standard……….18
3.0 RESEARCH METHODOLOGY…………..………..23
3.1 Introduction………...……..………23
3.2 Research Methodology……….……….23
3.3 Data Collection……….……….26
3.3.1 Field Observation……...……….……….26
3.3.2 Self Observation…..……….……….26
3.3.3 Measuring Device.…….….……….……….26
3.4 Data Analysis………...……….……….27
3.5 Project Time Line Gantt Chart……….……….28
4.0 RESULTS………....……….………..29
4.1 Introduction………...…...…..…….…29
4.2 Field Observation Result………...…...…..…….…29
4.3 Self Observation Result….………...…...…..…….…30
4.4 Overall Sections Result………...…...………...…...…..…….…30
4.4.1 Cell Line 1 Section……...……….……….31
4.4.2 Cell Line 2 Section……....……….……….32
4.4.3 Power Press Section……....……….……….32
4.4.4 Other Section……....…………..………….……….33
4.5 Overall Machines Result.………..………...……..…….…36
4.5.1 Power Press (250T) Machine…..……...….……….36
4.5.2 Power Press (200T) Machine..……….……….37
4.5.3 Power Press (60T) Machine……….……….37
4.5.4 Buffing Machine……....….…..………….……….38
4.5.5 CNC Punching Machine (Vipros)……….……...……….39
4.5.6 CNC Punching Machine (Murata)……….…..……….39
5.0 DISCUSSION………..……….………..41
5.1 Introduction……….………..………...……..…….…41
5.2 Cell Line 1 Section………….…….…..……...….……….41
5.3 Cell Line 2 Section………...……….……….43
5.4 PowerPress Section………….….……….……….45
5.5 CNC Section……….…....….…..………….……….47
5.6 Time Weighted Average Noise (TWAN)……….………...……..…….…49
5.6.1 Cell Line 1 Section…………..…….…...….……….50
5.6.2 Cell Line 2 Section…………..……….……….50
5.6.3 CNC Section………...……….……….50
5.6.4 Bending Section...……....….…..………….……….51
5.6.5 Power Press Section……….……….……...……….51
5.6.6 Robot Welding Section………….……….…..……….51
5.6.7 Overall Result………..………….……….…..……….52
5.7 Noise Dose……….………...……..…….…52
5.7.1 Cell Line 1 Section…………..…….…...….……….52
5.7.2 Cell Line 2 Section…………..……….……….53
5.7.3 CNC Section………...……….……….53
5.7.4 Bending Section...……....….…..………….……….53
5.7.5 Power Press Section……….……….……...……….54
5.7.6 Robot Welding Section………….……….…..……….54
5.7.7 Overall Result for Noise Dose………..……….55
5.8 Combination of Different Sources Simultaneously……….…………...…55
5.9 Comparison Results with Standard……….……….…………...…57
6.0 CONCLUSION AND RECOMMENDATION………..………...…………..60
6.1 Introduction………...…...…..…….…60
6.2 Conclusion…………..………...…...………...…...…..……..…60
6.3 Recommendation…………..……….…...………...…...…..……..…62
6.3.1 Permissible Exposure Limit…………..….……….62
6.3.2 Hearing Protection…………..……….……….62
6.3.3 Warning Sign at Critical Area….………….……….66
6.3.4 Training and Awareness...……....….…….……….67
6.3.5 Enforcement by the Administration………..…...……….67
6.3.6 Machine Improvement.………….……….…..……….67
6.3.7 Future Study………...………..……….68
REFERENCES………..………...………..69
APPENDICES
Appendix A – Result of Data Collection
Appendix B – Self observation Form
Appendix C – Teknion Furniture System Plan Layout
Appendix D – FMA Regulation 1989;
– Part II – Permissible Exposure Limit, Regulation 5
– Part V – Hearing Protection Devices, Regulation 17
Appendix E – Table of Weighted Sound Level
Appendix F – Sound Level Meter User Guide
LIST OF FIGURES
2.1 Some ISO Standards for Ergonomics (Bridger, 2003) 10
2.2 Model 407730 15
2.3 Weighted Sound Levels 17
2.4 Recommended Exposure Limit by NIOSH 20
2.5 Daily Noise Dose Percentage 21
2.6 Permissible Exposure Limits 22
3.1 Research Methodology 25
4.1 Cell Line 1 Noise Level 31
4.2 Cell Line 2 Noise Level 32
4.3 Power Press Noise Level 33
4.4 CNC Section Noise Level 34
4.5 Bending Section Noise Level 34
4.6 Robot Welding Section Noise Level 35
4.7 Power Press Machine (250T) Noise Level 36
4.8 Power Press Machine (200T) Noise Level 37
4.9 Power Press (60T) Machine Noise Level 38
4.10 Buffing Machine Noise Level 38
4.11 CNC Punching Machine (Vipros) Noise Level 39
4.12 CNC Punching Machine (Murata) Noise Level 40
5.1 Cell Line 1 Floor Layout 42
5.2 Buffing Machine 42
5.3 Inside the Cell in Cell Line 1 Section 43
5.4 Layout Cell Line 2 Section 44
5.5 Inside the Cell in Cell Line 2 Section 44
5.6 Layout Power Press Section 45
5.7 Operator Did Not Wear Earplug While Operating the Machine 46
5.8 Layout CNC Section 47
5.9 Operator Did Not Wear Earplug/Earmuff While Operating the
Machine
48
5.10 Only One Earmuff Provided in CNC Section 49
6.1 Sample of Silencer 67
LIST OF TABLES
2.1 Typical Sound Pressure Levels 11-12
2.2 Exposure Times versus Noise Level 13
2.3 Model 407730 General Specification 16
2.4 OSHA's Permissible Noise Exposure Levels 18
2.5 Permissible Noise Exposure Level For Above 80 Decibels 19
4.1 Average Noise Level in Selected Area of the Plant 30
4.2 Average Noise Level for Machines 36
5.1 Noise Dose Result 55
5.2 Comparison between Three Standards Used to Determine Noise
Exposure Level (For Each Section)
58
5.3 Comparison between Three Standard Used to Determine Noise
Exposure Level (For Each Machine)
58
6.1 Recommended Hearing Protection for Each Section 64
6.2 Recommended Hearing Protection for Machines User 65
6.3 Recommended Warning Sign 66
LIST OF ABBREVIATIONS, SYMBOLS, SPECIALIZED
NOMENCLATURE
ANSI - American National Standards Institute
FMA - Factory and Machinery
ISO - International Organization for Standardization
NIOSH - National Institute for Occupational Safety and Health
OSHA - Occupational Safety and Health Administration
PPE - Personal Protective Equipment
PSM - Projek Sarjana Muda
T - Ton
TWAN - Time Weighted Average Noise
UTeM - Universiti Teknikal Malaysia Melaka
1
CHAPTER 1
INTRODUCTION
1.1 Introduction
Nowadays ergonomics become one of the current goals to achieve in every fields
or work. Many of us still did not realize the importance of ergonomics in their daily life.
Ergonomics can be broken down into many components that affect our daily life. They
usually involve the comfort of human whether in the working area, surrounding
environment and also the posture of the human body. All of these components will
become hazards to human if not corrected as soon as possible.
We do our work in the surrounding environment that we think are safe to be in.
this is actually not correct because even in the controlled area, the environment can still
be danger to human. In the ergonomics aspect, environment consists of the air we
breathe, the temperature around us, the sound we hear and the visual we see. Out of these
factors stated above, we only care about the air we breathe. If the air were polluted, then
the environmental will become hazard to us. We did not know or care that other type of
environmental factors that can cause danger to us.
One of the most common factors that always been ignore by the worker and
employee is the sound occur when working. Sound can be separate into two categories
which is normal sound that we hear every day and the other one is noise. Noise occurs
when the sounds that we hear exceed the limit and the sound can hurt our ears. Most of
us cannot differentiate between sound and noise because we always think that both of it
is the same. That is why many people just ignore the noise around them and did not try to
2
Sound in the higher state called noise, can be very intimidating and disturbing our
peacefulness. In the short term, the noise did not bring any side effect to us but in the
long term it can possibly hurt our hearing system. The noise can cause human to loose
their hearing ability that is very important in every day routine. Most of us did not even
know that we have trouble hearing until we become old.
From the reasons above, a research will be done in the noise issues in the working
areas at a furniture industry. Even though there were several researches done in the
furniture industry, none of it was done under the environmental subject. The main goal of
this research is to determine the noise condition in Teknion Malaysia. Noise is one of the
common environmental issues but sometimes never been given serious attention by the
3
1.2 Statement of Problem
Nowadays, there is not much research done in the furniture industry. Same as
other major type of industries, furniture industry also facing the same environmental
issues especially noise level exposure. On that reasons, the study will be conduct in
furniture industry under noise monitoring for worker in furniture industry.
1.3 Objectives
The objectives of this research are:
1. To determine the noise level in selected furniture industry.
2. To collect data, make a comparison and analysis on noise level by referring
to OSHA standard or Factories and machinery act.
3. To give recommendation for the improvement on working condition of
people in the factory.
1.4 Scope
This research will be done only in Teknion Furniture System (M) Sdn Bhd. The
focus of this research is the noise level occurs in the critical section of the factory. A self
observation will be done in Manufacturing B section. The equipment that will be used in
this research is Extech Digital Sound Level Meter Model 407730. This equipment is
1.4 Company Background
In year 1995, Teknion furniture system Malaysia was set up in Tangkak, Johor.
The first manufacturing was commencing with 16 employees in 35,000 square feet of
manufacturing floor. The earliest product were manufactured in Malaysia is T.O.S
products.
When the age of Teknion reach four years old, the company shift their factory in
Klang, Selangor. The new factory was built on 180,000 square feet of ground which give
the company better space of manufacturing. With the new facilities, Teknion Malaysia
introduced three more new products ranging from seating, filling and storage product.
The new facilities give better production lines which extend the capabilities of Teknion
in Asia, Middle East and in India. The brisk improvement in Teknion Malaysia is a part
of the prime growth in Teknion history.
Teknion furniture system does not only manufacture furniture, they also strive to
understand the problems in work place. With the company motto “DESIGN DOES
MATTER”, they challenge themselves to come up with new and the best solution for
work place problems. Customer’s satisfactions were one of their goals to achieve every
year.
They have five major missions to archive which is to expand Teknion market
coverage within the Asia Pacific Rim to achieve a turnover of RM500 million (C$200
Million). Second, increase Teknion technology driven manufacturing capacity with
700,000 sq. ft of manufacturing space. Third, introduce new quality products offerings
adaptable to regional demands. Fourth, be committed to increase our workforce to 800
personnel managed by quality Human Resources Development programmes. The fifth
mission is continued to ensure Teknion Malaysia is known as a caring organization and is
recognized for excellence in quality, growth and profitability.
Teknion Vision stated that they shall be the total office solutions provider with
world class products and services that enrich the quality of life.
5
“We strive to consistently provide product and service which exceed our
customer expectations!” is Teknion quality statement.
Teknion general information:
Company Name Teknion Furniture System (M) Sdn Bhd
Location
Lot 761, Jalan Haji Sirat,
Off Jalan Meru,
42100 Klang,
Selangor Darul Ehsan, Malaysia.
Telephone/Fax 603-3342 4345 / 603-3343 5100
Website http://www.teknion.com
activities -Teknion Furniture System (M) Sdn Bhd is one of the Teknion
branch. The main headquarter is in Toronto, Canada and the
company is listed on the Toronto Stock Exchange (TSE) using the
symbol TKN.
-First plant was established in Tangkak, Johor in 1995. Starting with
16 employees producing components for T/O/S line of office
furniture in 35000swuare feet of manufacturing space.
-In 1999, Teknion Malaysia acquired a leading Malaysian
Manufacturer of filling, storage and seating products. Included in the
acquisition was a 180,000 square foot facilities in Klang. This
significantly helps Teknion improved their manufacturing
capabilities in Asia for distribution in Asia, Middle East and India.
-Teknion does more than manufacture furniture. They strive to
understand the needs and challenges of the workplace and design the
real solution that will meet those needs today and in the future.
-Teknion’s key to continue success is to focus on understanding the
real challenges of the working world. Teknion will continue to
design, manufacture and deliver the highest quality office solutions
6
CHAPTER 2
LITERATURE REVIEW
2.1 Introduction
In this chapter, several literatures will be review regarding the title of the project.
All aspects and subject involved within the project scope will be highlighted. There are
three main fields that involved in this chapter which are Ergonomics, environmental and
Furniture Industry. There were many journal and book referring to the project scope.
From the broad area, the review then highlighted a main issue which is noise level.
Literature review works as a guideline and better understanding to the field of project. It
helps to identify the current problems, information, new techniques, and method of study,
solution and recommendation.
2.2 Ergonomics Characterization
Ergonomics was first defined as the scientific study of the relationship between
man and his environment by Murrell, 1950. Nowadays, ergonomics was defined as a
study of work and its environment and conditions in order to achieve maximum
efficiency (Hawkins et al. 1998). For engineering purpose, ergonomics known as a
multidisciplinary science that seeks to conform the workplace and all of it physiological
aspect to the worker. Ergonomics involves the following criteria: using special design
and evaluation techniques to make task, objects, and environments more compatible with
human abilities and limitation. The second criterion is seeking to improve productivity
and quality by reducing workplace stressor, reducing the risk of injuries and illnesses and
7
Ergonomics can be divided into three categories. The first category is physical
ergonomics which involved with human anatomical, anthropometric, physiological and
biomechanical. The second category is cognitive ergonomics which concern about
mental process. The third category is organizational ergonomics that optimize the
sociotechnical system including organizational structures policies and process.
2.2.1 Ergonomics History
In 1857, Jastrzebowski produced a philosophical treatise on ‘An Outline of
Ergonomics or the Science of Work’ but it seems to have remained unknown outside
Poland, until recently. In Britain, the field of ergonomics was inaugurated after the
Second World War. The name was re-invented by Murrell in 1949 despite the objections
that people will confuse it with economics (Bridger, 2003).
Christensen (1987) points out that the importance of a “good fit” between
humans and tool was realized early in the development of species. The early species
called Australopithecus Prometheus used pebble tools and antelope bones to made
scoops to make their tasks easier. Nowadays, the selection or creating tools, machines,
and work process is still continued. The birth of machines such as the spinning jenny (a
machine that produced yarn to make cloth) and rolling mills (a method of flattening iron
ore into flat sheets) in the Industrial Revolution era were made to improve the work
process. This type of improvement is the common motivation of ergonomics today
(http://www.ergoweb.com/resources/faq/history.cfm).
In the late 19th century, Frederick W. Taylor finished several studies in
ergonomics. When the studies were finished, it gives the Business area a strong base of
understanding which clearly define the current outlook on work. Frederick’s studies were
recognize in the Business are and he was name the father of Scientific Management.
Mainly, Taylor was interested in a scientific management which is to improve the
working condition for the middle class by leveling a large scale changes in
manufacturing process. From the help of his group and self motivation, he came up with
8
Scientific Management, developed by F. W. Taylor, and workstudy, developed by
the Gilbreths, is precursors of ergonomics (Bridger, 2003). Both of Taylor and Gilbreths
came up at the early of 20th century. They were focusing the awareness of improving
productivity by changing the way of work done. In that time, many company hired a
foremen to arrange their factory plant. This decision was decided by the foremen and did
not involve the owner. It’s the foremen job to arrange the machine and work station the
best that they could come up. The manager’s only concern about the output of the factory
produced but did not give any attention to the working condition. The worker will get
incentives for improvement suggested and the income we hang on the foremen that
arrange the work.
Taylor did not agree with the trend because it will lead to corruption and
exploitation of worker. Taylor emphasis that every job, no matter how small, was worthy
of study and improvement (Bridger, 2003). Taylor stress out that the management team is
responsible for what action to take in order to maximizing the return profits, for top and
lower management including worker. In every task, it should be broken down into
simplest form, given a brief explanation would help worker maximize their output
productivity.
In the 1920s and early 1930s a series of experiments were carried out over 12
years by Elton Mayo and his colleagues at the Hawthrone Works of the Western Electric
Company in the USA (Bridger, 2003). Their experiments were historical for the social
factors at work. The investor began by examining the effect of illumination, rest pauses
and shorter hours on productivity and fatigue but soon ran into difficulties because they
were
Trying to maintain a controlled experiment in which they could test for the effect
of single variables while holding all other factors constant... By Period XIII it had
become evident than in human situations, not only was practically impossible to keep all
other factors constant but trying to do so in itself introduced the biggest change of all; in
other words the investigators had not been studying an ordinary shop situation but a
socially contrived situation of their own making (Rothlisberger and Dickson, 1939)
