final inspection assessment at car manufacturing plant

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USING REBA AND NORDIC BODY MAPS

By

Herli Inda Marselianto 11607021

BACHELOR’S DEGREE in

INDUSTRIAL ENGINEERING

FACULTY OF ENGINEERING AND INFORMATION TECHNOLOGY

SWISS GERMAN UNIVERSITY The Prominence Tower

Jalan Jalur Sutera Barat No. 15, Alam Sutera Tangerang, Banten 15143 - Indonesia

July 2020

Revision after the Thesis Defense on 8 July 2020

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Herli Inda Marselianto STATEMENT BY THE AUTHOR

I hereby declare that this submission is my own work and to the best of my knowledge, it contains no material previously published or written by another person, nor material which to a substantial extent has been accepted for the award of any other degree or diploma at any educational institution, except where due acknowledgement is made in the thesis.

Herli Inda Marselianto

_____________________________________________

Student Date

Approved by:

Ir. Triarti Saraswati, M.Eng

_____________________________________________

Thesis Advisor Date

Dr. Tanika Dewi Sofianti, S.T, M.T

_____________________________________________

Thesis Co-Advisor Date

Dr. Maulahikmah Galinium, S.Kom, M.Sc

_____________________________________________

Dean Date

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Herli Inda Marselianto ABSTRACT

FINAL INSPECTION ASSESSMENT AT CAR MANUFACTURING PLANT USING REBA AND NORDIC BODY MAPS

By

Herli Inda Marselianto Ir. Triarti Saraswati, M.Eng Dr. Tanika Dewi Sofianti, S.T, M.T

SWISS GERMAN UNIVERSITY

This research study is based on cases in the final inspection department at car manufacturing plants which the company produces many varieties of automobiles and engines. In the final inspection area, some problems have a big impact on the inspectors’

performance which are fatigue and pain on several parts of the body. The main objective of this thesis is to improve the final inspection department performance by assessing all the inspectors with REBA and Nordic Body Maps. The inspectors’ posture observed and gathered then data can be analyzed through REBA and Nordic Body Maps to find the root cause of the problem. After the root cause is defined by REBA and Nordic Body Maps, the root causes processed by a suitable solution for each inspection process based on the root cause. The inspection which has trouble with posture was given suitable improvement for the best interaction between inspectors and section.

Therefore, the improvement should prevent the root cause which the problem is a risky posture for the inspectors. The improvement conducted by supporting tool(s), standardized work process, and redesign task. As the result, it gave an improvement in the quality control area and avoiding miss quality checking because of fatigue and pain on several parts of the body.

Keywords: Ergonomics, Nordic Body Maps. REBA, Supporting Tool(s), Final Inspection.

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Herli Inda Marselianto DEDICATION

I dedicate this works to my family, my supervisors, my company for this project, friends, and my lecturers in Industrial Engineering of SGU.

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Herli Inda Marselianto ACKNOWLEDGEMENTS

First, I would like to give my biggest gratefulness to God for giving me the health and the support that allows me to complete this thesis work.

I wish to thank my family and my parents for their support, love, and advice. I would like to give thanks to my advisor for giving me a gentle but firm direction, patience, and unlimited support to complete my thesis. I would like to appreciate my project place and my supervisors in the car manufacturing plant company for allowing me to learn and give me all the sources of this research study.

At last, I would like to give my big thanks to my friend from the Industrial Engineering batch of 2016 along the time we spent together in SGU. Thank you for all the memories and thank you for being my second family.

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Herli Inda Marselianto TABLE OF CONTENTS

STATEMENT BY THE AUTHOR ... 2

ABSTRACT ... 3

DEDICATION ... 5

ACKNOWLEDGEMENTS ... 6

TABLE OF CONTENTS ... 7

LIST OF FIGURES ... 10

LIST OF TABLES ... 12

CHAPTER 1 - INTRODUCTION ... 14

1.1 Background ... 14

1.2 Research Problems ... 15

1.3 Research Objectives ... 15

1.4 Research Limitation ... 15

1.5 Thesis Structure ... 16

CHAPTER 2 - LITERATURE REVIEW ... 17

2.1 Quality Control ... 17

2.2 Ergonomics ... 17

2.2.1 Anthropometry ... 18

2.3 Working Environment ... 19

2.4 Health Issues in Quality Control ... 19

2.4.1 Fatigue ... 19

2.4.2 Cumulative Trauma Disorder (CTD) ... 20

2.5 Six Sigma (DMAIC) ... 20

CHAPTER 3 – RESEARCH METHODS ... 22

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3.2 Literature Review ... 23

3.3 Data Collection ... 23

3.3.1 Interview ... 23

3.3.2 Nordic Body Maps ... 24

3.3.3 Observations ... 26

3.4 Data Processing ... 26

3.5 Data Analysis ... 27

3.5.1 REBA (Rapid Entire Body Assessment) ... 27

3.5.2 Task Analysis ... 32

3.6 Propose Improvement ... 33

3.7 Monitor Results and Processes ... 33

3.8 Recommendations and Conclusion ... 33

CHAPTER 4 – RESULTS AND DISCUSSIONS ... 34

4.1 Introduction to Company ... 34

4.1.1 Company Profile ... 34

4.1.2 Organizational Structure in Final Inspection Department ... 35

4.1.3 Flowchart Process in Final Inspection Department ... 37

4.2 Initial Evaluation ... 43

4.2.1 REBA Score ... 44

4.2.2 Nordic Body Maps ... 58

4.3 Data Analysis ... 63

4.3.1 Wheel Alignment Analysis ... 65

4.3.2 Under-pit Analysis ... 69

4.4 Propose Improvement ... 72

4.4.1 Standardized Work Process ... 73

4.4.2 Supporting Tools ... 77

4.4.2.1 Wheel Alignment Process ... 78

4.4.2.2 Under-pit Process ... 79

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4.4.3.1 Wheel Alignment Process ... 82

4.4.3.2 Under-pit Process ... 85

4.4.4 Summary ... 87

4.4.5 Monitor Results and Processes ... 88

CHAPTER 5 – CONCLUSIONS AND RECOMMENDATIONS ... 90

5.1 Conclusions ... 90

5.2 Recommendations ... 91

GLOSSARY ... 92

REFERENCES ... 93

APPENDICES ... 94

APPENDIX A-Nordic Body Maps ... 95

CURRICULUM VITAE ... 139

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Herli Inda Marselianto LIST OF FIGURES

Figures Page

Figure 3.1. Research Methods ... 22

Figure 3.2. Nordic Body Maps Form (Bakri, et al., 2004) ... 25

Figure 3.3. REBA Neck Posture (Middlesworth, 2015) ... 28

Figure 3.4. REBA Trunk Posture (Middlesworth, 2015) ... 29

Figure 3.5. REBA Legs Posture (Middlesworth, 2015) ... 29

Figure 3.6. REBA Upper Arm Posture (Middlesworth, 2015) ... 30

Figure 3.7. REBA Lower Arm Posture (Middlesworth, 2015) ... 30

Figure 3.8. REBA Wrist Posture (Middlesworth, 2015)... 31

Figure 4.9. Organizational Structure of the Final Inspection Department ... 35

Figure 4.10. Flowchart Process in Final Inspection ... 37

Figure 4.11. Wheel Alignment & Turning Radius Illustration. Image downloaded from https://www.durr.com/en/products/testing-systems/wheel-alignment/wheel- alignment-passenger-cars/ in March 2020. ... 38

Figure 4.12. Wheel Alignment & Turning Radius Illustration 2. Image downloaded from https://www.dimensions.com/collection/vehicle-turning-paths-radius in March 2020. ... 38

Figure 4.13. Headlight Tester Illustration. Image downloaded from https://www.maha.com.au/digital-headlight-tester-mlt3000/ in March 2020. ... 39

Figure 4.14. Side Slip Illustration. Image downloaded https://www.xedra- automotive.com/English/product_97/dynamic-side-slip-tester-car-lcv.html in June 2020. ... 40

Figure 4.15. Drum & Brake Tester Illustration. Image downloaded from https://www.anzen.co.jp/english/products/ in June 2020. ... 41

Figure 4.16. Under-pit Illustration. Image downloaded from https://www.flickr.com/photos/66017427@N06/6009542286/ in March 2020 ... 42

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http://www.paindoo.com/picture-8430 in March 2020. ... 42

Figure 4.18. Body Posture in Wheel Alignment ... 44

Figure 4.19. Body Posture in Turning Radius Meter ... 45

Figure 4.20. Body Posture in Headlight Tester ... 46

Figure 4.21. Body Posture in Appearance Inspection ... 48

Figure 4.22. Body Posture in Drum Tester ... 49

Figure 4.23. Body Posture in Brake Tester ... 50

Figure 4.24. Body Posture in Side Slip Tester ... 51

Figure 4.25. Body Posture in Engine Room ... 52

Figure 4.26. Body Posture in Under-pit ... 53

Figure 4.27. Body Posture in Shower Test ... 55

Figure 4.28. Body Posture in Rattle Noise... 56

Figure 4.29. Body Posture in High Speed ... 57

Figure 4.30. Wheel Alignment Work Area Dimension Illustration ... 65

Figure 4.31. Under-pit Work Area Dimension Illustration ... 69

Figure 4.32. Inspection Process Flow in Under-pit Inspection ... 75

Figure 4.33. Proposed Inspection Process Flow in Under-pit Inspection ... 76

Figure 4.34. Gas Spring Desk Picture. Image downloaded from https://uae.microless.com/product/neckdoctor-for-desk-the-original-ergonomic-gas- spring-single-monitor-arm-stand-for-13-to-32-monitors-neckdoctor-desk/ in May 2020. ... 78

Figure 4.35. Ergo Arm Rest Picture. Image downloaded from https://www.ergoexperts.com/products/ergorest-articulating-arm-rest in May 2020. . 79

Figure 4.36. Spotlight Lamp Picture. Image downloaded from https://www.walmart.com/ip/Mainstays-7-5-Spotlight-Accent-Lamp-Black- Finish/21881768 in April 2020. ... 80

Figure 4.37. Cave Headlamp Picture. Image downloaded from https://eurotravel360.com/tag/led-headlamp/ in April 2020. ... 80

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Herli Inda Marselianto LIST OF TABLES

Tables Page

Table 3.1. Nordic Body Maps Risk Level ... 26

Table 3.2. Level of REBA Score Risk (Middlesworth, 2015) ... 28

Table 3.3. Table A REBA Scoring (Middlesworth, 2015) ... 30

Table 3.4. Table B REBA Scoring (Middlesworth, 2015) ... 31

Table 3.5. Table C REBA Scoring (Middlesworth, 2015) ... 32

Table 4.6. Total Manpower Each Section ... 36

Table 4.7. REBA Calculation Table for Wheel Alignment Process ... 44

Table 4.8. REBA Calculation Table for Turning Radius Process ... 45

Table 4.9. REBA Calculation Table for Headlight Process ... 47

Table 4.10. REBA Calculation Table for Appearance Inspection ... 48

Table 4.11. REBA Calculation Table for Drum Tester Process ... 49

Table 4.12. REBA Calculation Table for Brake Tester Process ... 50

Table 4.13. REBA Calculation Table for Side Slip Inspection ... 51

Table 4.14. REBA Calculation Table for Engine Room Inspection ... 52

Table 4.15. REBA Calculation Table for Under-pit Process ... 54

Table 4.16. REBA Calculation Table for Shower Test Inspection ... 55

Table 4.17. REBA Calculation Table for Rattle Noise Inspection ... 56

Table 4.18. REBA Calculation Table for High-Speed Inspection ... 57

Table 4.19. Nordic Body Maps All Data ... 59

Table 4.20. Summary of Nordic Body Maps Data ... 63

Table 4.21. REBA Score Priority Table ... 64

Table 4.22. Wheel Alignment Analysis Table ... 66

Table 4.23. Wheel Alignment Healing Action Table ... 68

Table 4.24. Under-pit Analysis Table ... 70

Table 4.25. Under-pit Healing Action Table ... 72

Table 4.26. Comparison Table for Spotlight Lamp and Headlamp ... 81

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Herli Inda Marselianto Table 4.28. REBA Score Table after Redesign Task Using Gas Spring Desk in Wheel Alignment Process ... 83 Table 4.29. REBA Score Table after Redesign Task Using Gas Spring Desk and Arm Rest in Wheel Alignment Process ... 84 Table 4.30. REBA Score Table before Redesign Task in Under-pit Process ... 85 Table 4.31. REBA Score Table after Redesign Task Using Spotlight Lamp or

Headlamp in Under-pit Process ... 86 Table 4.32. REBA Score Table after Redesign Task Using Spotlight Lamp or

Headlamp and Standardized Work Process in Under-pit Process ... 87 Table 4.33. Summary REBA Score after Improvement ... 87 Table 4.34. Audit Checklist ... 89