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

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