Vol 8, No 2 (2017) > Industrial Engineering >

Redesign of Liquid Aluminum Pouring Tool based on Participatory Ergonomics to Improve Productivity, Workload, and Musculoskeletal Disorders

Hafzoh Batubara, Rini Dharmastiti

 

Abstract: This research was
conducted at P.T. “ED” Aluminium, Yogyakarta, an industrial aluminum
foundry that produces manually operated cooking appliances. The workers
complain of muscle pain and fatigue, and of always having to pursue production
targets in order to fulfill goods shipment deadlines. Also evident was the
unergonomic work system, where the liquid aluminum was often spilled due to
workers having to adopt an unnatural work posture when pouring the liquid
aluminum into molds. Therefore, the researchers’ aims were to improve the
operator’s working posture, reduce the workload, eradicate musculoskeletal
complaints, improve time efficiency, and increase productivity
by redesigning the liquid aluminum pouring tools using an integrated
participatory ergonomics method combined with an appropriate technology (AT)
concept. Furthermore, ergonomics intervention was conducted in the
redesigning of the pouring tools. The result was an ergonomic liquid
aluminum pouring tool. The ergonomics intervention results from use of the
newly designed pouring tools allowed for a more natural working
posture, improvement in the workload category from heavy to medium, a
26.13% reduction of the workload, and a 19.64% reduction in musculoskeletal
disorders. Time efficiency increased by 25.81%, and productivity
increased by 26.60%.
Keywords: Liquid aluminum pouring tool; Musculoskeletal disorder; Participatory ergonomics; Workload

Full PDF Download

References


Batubara, H., 2010. Work System Evaluation based on Ergonomics. P.T. “ED” Alumunium Yogyakarta, In: Proceedings of the International Joint Conference APCHI-ERGOFUTURE 2010, 2nd–6th August, Bali

Cheung, Z., Feletto, M., Galante, J., Waters, T., 2007. Centers for Disease Control and Prevention, Ergonomic Guidelines for Manual Material Handling. In: NIOSH Publication (No. 2007-131), NIOSH

Christensen, J.H., Christensen, M.S., Dyerberg, J., Schmidt, E.B., 1999. Heart Rate Variability and Fatty Acid Content of Blood Cell Membranes: A Dose-response Study with n-3 Fatty Acids. The American Journal of Clinical Nutrition, Volume 70(3), pp. 331–337

de Jong, A.M., Vink, P., 2002, Participatory Ergonomics Applied in Installation Work. Applied Ergonomics, Volume 33(5), pp. 439–448

Grandjean, E., 1989. Fitting the Task to the Man: A textbook of Occupational Ergonomics. Taylor & Francis/Hemisphere, London

Grandjean, E., Kroemer, 2000. Fitting the Task to the Human. A textbook of Occupational Ergonomics, 5. Taylor & Francis Inc. London

Hess, J.A., Hecker, S., Weinstein, M., Lunger, M., 2004. A Participatory Ergonomics Intervention to Reduce Risk Factors for Low-Back Disorders in Concrete Laborers, Applied Ergonomics, Volume 35 (5), pp. 427–441

Hignett, S., Wilson, J.R., Morris, W., 2005. Finding Ergonomic Solutions—Participatory Approaches. Occupational Medicine, Volume 55(3), pp. 200–207

Louhevaara, V., Kilbom, A., 2005. Dynamic Work Assessment. In: Evaluation of Human Work, CRC Press, Boca Raton, pp. 429–451

Manuaba, A., 2003. Penerapan Ergonomi Meningkatkan Produktivitas, Makalah. Denpasar: Bagian Ilmu Faal Fakultas Kedokteran Universitas Udayana

National Obesity Observation, 2009. Body Mass Index as a Measure of Obesity. Available online at http://www.noo.org.uk/uploads/doc789_40_noo_BMI.pdf Accessed on Jan 31, 2011

Oesman, T.I., 2014. Evaluasi Kondisi Lingkungan Kerja pada Bagian Proses Pengecoran di Industri Kerajinan Cor Alumunium PT “ED” Yogjakarta. Industrial and Systems Engineering Assessment Journal (INASEA), Volume 15(1), pp. 71–78

Permana, D., 2008. Tangga Rumah: Solusi Rancangan Cermat. Available online at http://daukhan-arsitek.com/2009/11/tangga-rumah-solusi-rancangan-cermat/ Accessed on May 11, 2011

Punnett, L., Wegman, D.H., 2004. Work-related Musculoskeletal Disorders: The Epidemiologic Evidence and the Debate. Journal of Electromyography and Kinesiology, Volume 14(1), pp. 13–23

Rupesh, K., 2006. Ergonomic Evaluation and Design of Tools in Cleaning Ooccupations. Doctoral Dissertation. Department of Human Work Sciences, University of Technology, Sweden

St. Vincent, M., Lortie, M., Chicoine, D., 2001. Participatory Ergonomics Training in the Manufacturing Sector and Ergonomic Analysis Tools. Relations Industrielles/Industrial Relations, Volume 56(3), pp. 491–515

Tarwaka, S.H., Sudiajeng, L., 2004. Ergonomi untuk Keselamatan,

Kesehatan Kerja dan Produktivitas. UNIBA, Surakarta

Wells, R., Norman, R., Frazer, M., Laing, A., Cole, D., Kerr, M., 2003. Participative Ergonomic Blueprint, Institute for Work & Health, Toronto

Wickens, C.D., Gordon, S.E., Liu, Y., Lee, J., 1998. An Introduction to Human Factors Engineering, Pearson Education, Upper Saddle River, New Jersey