Kamat 2017
Kamat 2017
Kamat 2017
To cite this article: S. R. Kamat et al 2017 IOP Conf. Ser.: Mater. Sci. Eng. 210 012079 - Work-related musculoskeletal disorders
(WMDs) risk assessment at core assembly
production of electronic components
manufacturing company
N M Yahya and M N O Zahid
Recent citations
- Nur Syafiqah Rayme et al
E-mail: *[email protected]
1. Introduction
Ergonomic comes from Greek word which means “work law”, it also describes as “the effort to fit the
system to the human” which means that to fit the unique human limitation and abilities by selecting
and designing the informed decision, tasks, environment, tools and equipment. The dimensions that
define ergonomics discipline include philosophy, theory, technology or environment, management,
design, practice and education [1]. The main focus of this study is to improve the ergonomics body
posture of workers in the aerospace manufacturing company.
The warehouse of the aerospace manufacturing company had been chosen because the working
process design in the building involves repetitive task and heavy lifting activities. The risk of
ergonomics can be seen affecting the workers in the building as they had complained about them
experiencing fatigue and pains at certain areas of the body especially at the lower back of the body.
The complaints had been retrieved through the distributed questionnaires. All those symptoms and
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IOP Conf. Series: Materials Science and Engineering 210 (2017) 012079 doi:10.1088/1757-899X/210/1/012079
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effects will greatly contribute to repetitive stress injuries (RSIs) and musculoskeletal disorder (MSDs).
Both are known as parts of ergonomic injuries. Ergonomics injuries are the bad effects that caused by
the existence of the ergonomics risk factors such as awkward postures, sustained postures, contact
pressure, forceful exertion, forceful strain and exposure to vibration, heat or cold. When the risk
factors combined, and exerted on the worker through a continuous period, the risk factors will lead to
injury, pain and disability. As example, in a manufacturing company, if an injury occurs, the
dangerous single event will place a stress on body tissues. Although the tissues are capable to recover
its condition, the repetitions of the hard manufacturing activity that cause the injury will slower the
healing process.
1.2. Objectives
Based on the problems arise related to the repetitive and heavy manual lifting activities in the
warehouse, the objectives of the study are;
i) To investigate about the body posture of the workers while doing repetitive and heavy lifting
activities in the warehouse.
ii) To analyse the discomfort body posture of the workers while undertaken the repetitive and
heavy lifting activities that cause the musculoskeletal disorder problems.
iii) To suggest the proper body posture and ways to reduce the musculoskeletal disorder
problems.
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IOP Conf. Series: Materials Science and Engineering 210 (2017) 012079 doi:10.1088/1757-899X/210/1/012079
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been considered in this study are the requirement of the working activities, ergonomics obligation,
ergonomics problems and ergonomic principles.
In advance, other aspects such as NIOSH lifting equation, anthropometric measurement, muscle
fatigue, musculoskeletal disorder (MSDs) and repetitive stress injuries (RSIs) had been enclosed in
this study. The software that had been used to analyse the working body posture is CatiaV5. The
working body posture analysis had been done to prove the effectiveness of the body posture
improvement. However, the result of the study is only based on the simulation. There are no
fabrication activities and real implementation occurred in order to test the suggested improvement.
This study did not cover the labour productivity issue.
2. Literature reviews
Like in any other manufacturing industry, an aerospace manufacturing industry is also exposed to
manufacturing activities that can risk the workers to the ergonomic risk factors [2]. It is important for a
manufacturing industry to implement ergonomics technique in the working area because with the
existence of proper ergonomics application; cost can be reduced, productivity level can be improved,
quality of working can be increased, employee engagement can be improved and better safety culture
can be created.
Ergonomics risk factor conferred by the United Stated Occupational Safety and Health
Administration includes work environment, body posture, forceful exertion, prolonged static load,
repetition, lack of rest and improper aid [3]. Thus, it is necessary for the employer to make sure that
the ergonomics risk factor in the worker workstation is at the possible lowest term. In addition to
musculoskeletal disorder leading to medical expenses, the ergonomics risk factor can leads to overtime
wage, cost of training and hiring for replacement, loss of productivity, management cost and other
miscellaneous charges.
In order to offer the worker the finest man-machine boundary and the required adjustability with
the aim to prevent discomfort and workplace injuries, a good ergonomic design principles must be
practised [4]. An article named “Ergonomic: The backbone of a more productive warehouse”
mentioned that workstation design can give big influence on the ergonomic health of the workers and
the ergonomics workstation is all about body posture. Body posture while working can be categorised
to three types which are standing, sitting and both. The ability of the workstation’s features such as
length and height to be adjusted so that its features are compatible to workers anthropometry
measurement is a very good ergonomics workstation.
Rapid Upper Limb Assessment (RULA) is an assessment that used to analyse the disclosure of
workers to ergonomic risk related to upper extremity musculoskeletal disorder [5]. The things that are
mattered by the RULA ergonomic assessment tool are the postural load requirement and the
biomechanical of job demand especially on the trunk, upper extremities and neck. The evaluation of
the required body posture, repetition and force can be made by only single page worksheet. Both
scores for section A which is for the arm and wrist areas and for section B which is for the neck and
truck are must be inserted in order to obtain the evaluation score.
The manual handling operations regulation that was altered in 2002 is applied to the extensive
assortment of manual handling activities include pulling, pushing, lifting, carrying or lowering. The
type of loads may include living thing for instance animal or person, or non-living thing such as trolley
or box. It was discussed that the improper manual handling activity is one of the utmost typical causes
of the injury happened at workplace [6].
The musculoskeletal disorder can be the effect of the improper manual handling. The risk factors of
the MSDs development include; manual material handling, manual labour, awkward postures and
existing injury. Repetitive movement is a simple harmonic motion through back and forth movement
placed at the equilibrium or the centre point where the optimum displacement on one side is equal to
the optimum displacement on the other side as well [7]. The force used for the motion is always focus
on the equilibrium location and is directly proportional to the distance from it, and the time interval of
each complete vibration is equal to one another. In manufacturing industries, there are many repetition
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International Technical Postgraduate Conference IOP Publishing
IOP Conf. Series: Materials Science and Engineering 210 (2017) 012079 doi:10.1088/1757-899X/210/1/012079
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movements that have to be carried out in order to achieve the requirement of the manufacturing
activities. There are manufacturing activities like fitting, saw cutting, manual threading, painting, and
machining that requires the worker to work in repetitive movement for the task completion. In
warehouse, the manual material handling activity, wrapping activity and lifting activity can be seen as
the activities that require the worker to work in repetition motion. However, rapid movement of the
repetitive motion activities can risk the worker to the ergonomics injury.
Lifting is an activity in order to bring or move something upward generally from the ground or
other support elements to a higher location. In warehouse, it is the main activity that is involved.
Lifting in warehouse means to lift the inventory or equipment within the warehouse for receiving,
storing, wrapping and shipping purpose. However, if the object to be lifted is heavy and not
compatible with the worker, the situation can lead to injury. The biggest risk factors regarding to
lifting activity are the cumulative trauma and overexertion [8]. It is advisable for the workers to use
smart lifting techniques and only work in their own abilities so that they will be less exposed to muscle
pulls, wrist injuries, back sprains, elbow injuries, spinal injuries and any other related injury. There are
many causes that can contribute to all those injuries. Some of the causes are incompatible weightiness
of loads, awkward body postures, high frequency of materials to be lifted and long durations needed
for the lifting activities, inadequate handhold and environmental factors. The important aspects of
design are the human fit, function and form in the demanding global marketplace. The best in class
human modelling which is the human activity analysis permitted detailed investigation into human
centred designation issue regarding to workplace’s environment before it is existed. The way a human
being interacts with objects in working environment, the effects of lifting activities; pulling, carrying
task, lowering and pushing were the focus points of the human activities analysis. The equation used
to measure the effects of all those activities is the NIOSH 1981/1991 and Snook and Ciriello equation.
CATIA V5 promotes the solution towards ergonomic body posture in two main software tools [9]. The
first software tool which is the human measurement editor is used to create detailed digital human
model to extended analysis. It is capable of creating human manikin by using complex series of
advance anthropomorphic tools and by adaptation of smaller number of crucial variables. The software
human builder in CATIA which is the human builder consist from complex sets of tools that are
devoted to create the human digital model which called manikin, the manikin manipulation and the
interaction analysis with the product. In order to generate the view form, function and comfort, the
manikin can be used.
Other than the mentioned tools, CATIA had also provides the analysis of workstation assembly.
There are two other software modules has been created in order to fulfil the purpose which are the
human activity analysis and the human posture analysis. The interaction between the human and the
objects in the working area and the effects of the sinking, lifting, pressing and pulling can be analysed
by the human activity analysis software. The software is able to evaluate all the aspects of the human
effectiveness through the analysis of the static position to the complex activities by the execution of
tasks. The software enables the user to maximize the safety, the comfort and the efficiency by the
usage of wide spectrum of trolls to ergonomic analysis which involve complex evaluate the interaction
between the manikin and the objects in the virtual environment.
The RULA (Rapid Upper Limb Assessment), push and pull analysis, loading analysis by load lifting
according to NIOSH 1991, NIOSH 1981 and Snook & Ciriello, carry and biomechanical analysis. The
workstation can be created in accordance with health and safety standards by this tool in order to
maximize the safety and comfort. Next software tool provided by CATIA is the human posture
analysis which analyse the way human posture influences the productivity by the execution of task.
The tool can analyse preferred angles, the local and total postures and convenience. The user can do
the quantitative and quality analysis of all the aspects of the manikin postures through the module. In
addition, the model allows the user to test postures, generate the evaluation, optimized and iterated the
data.
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International Technical Postgraduate Conference IOP Publishing
IOP Conf. Series: Materials Science and Engineering 210 (2017) 012079 doi:10.1088/1757-899X/210/1/012079
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3. Methodology
The data collection started by the observation, interview sessions with manufacturing engineer and the
distribution of questionnaires to the workers in warehouse department. These are to contemplate with
the problem statement of the study. The next phase is the collection of anthropometry measurement of
the workers, Nordic questionnaires, photos and videos of the workers while doing their tasks in the
warehouse. The flowchart of the study is as in figure 1.
Several observations had been done in the warehouse including the procedure of working tasks, layout
and environmental of warehouse, type of body postures needed to conduct tasks and tools equipped to
the workers. Another method that had been used in order to gather the qualitative data is by
distributing questionnaires. The questionnaires were distributed to the workers in the company’s
warehouse. As for the pilot study, ten respondents has been chose for the questionnaires distribution.
The respondents were divided into two different categories which are for workers under 30 years old
and workers 30 years old and above. For the second phase of the study, more detailed questionnaires
had been distributed to twenty workers involving in manual handling activities in the warehouse. The
selected type of the questionnaire that will be distributed for the second phase of the project is the
Nordic type of questionnaire. The Nordic questionnaire is one of the most known survey tool to detect
musculoskeletal disorder [10]. Initially, the standardized Nordic questionnaires were created by an
organized Nordic researcher’s team. The main objective of the Nordic questionnaires creation is to
screen the musculoskeletal disorders and for epidemiological studies.
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International Technical Postgraduate Conference IOP Publishing
IOP Conf. Series: Materials Science and Engineering 210 (2017) 012079 doi:10.1088/1757-899X/210/1/012079
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4.1 Analysis of Body Posture of the Worker While Handling the Tasks
figure 2 shows the first worker is lifting 30 kilogrammes spoiler core up to 190meters height. The
critical working posture involve repetitive heavy lifting activities and awkward working body posture.
The frequency of lifting is 2 lift per minute. The middle worker in figure 2 shows a worker lifting a
box of vacuum bag sealant weighed 8 kilogrammes from the lower rack. The critical working posture
involve repetitive heavy lifting activities and awkward lifting body posture. The frequency of lifting is
3 lift per minute. The worker on the right in figure 2 shows worker is lifting a 7 kilogrammes box from
the top storey of a rack. The critical working posture involve heavy lifting activities and awkward
lifting body posture. The frequency of lifting is 3 lift per minute.
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International Technical Postgraduate Conference IOP Publishing
IOP Conf. Series: Materials Science and Engineering 210 (2017) 012079 doi:10.1088/1757-899X/210/1/012079
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International Technical Postgraduate Conference IOP Publishing
IOP Conf. Series: Materials Science and Engineering 210 (2017) 012079 doi:10.1088/1757-899X/210/1/012079
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International Technical Postgraduate Conference IOP Publishing
IOP Conf. Series: Materials Science and Engineering 210 (2017) 012079 doi:10.1088/1757-899X/210/1/012079
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International Technical Postgraduate Conference IOP Publishing
IOP Conf. Series: Materials Science and Engineering 210 (2017) 012079 doi:10.1088/1757-899X/210/1/012079
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Figure 10. RULA Analysis for Worker’s Body Posture While Using Portable Gantry Crane (Right
Side)
Figure 10 shows the RULA score which is 2 for right side of the body that can be obtained if the
manual lifting task inside the warehouse is replaced by the usage of the portable gantry crane. The
RULA score 2 is the desired RULA score as it indicates that the posture is acceptable if it is not
maintained or repeated for long periods of time [9]. It is favourable if the manual lifting task can be
replaced by the usage of automation system to avoid from musculoskeletal disorder problem [6]. The
portable gantry crane is an automated lifting equipment. The workers just have to control its axis
movement by clicking the switches on the crane.
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International Technical Postgraduate Conference IOP Publishing
IOP Conf. Series: Materials Science and Engineering 210 (2017) 012079 doi:10.1088/1757-899X/210/1/012079
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Figure 11 shows the RULA score pattern of the current working posture, improvised working posture
and the working posture aided with the design of lifting equipment. The decreasing pattern of the
RULA score along the improvement effort is good as the smaller the RULA score, the safer the
working posture is toward the ergonomic risk factor [9]. The decreasing value of RULA score from
current working posture to the improved working posture is lesser than the decreasing value of RULA
score from the improved working posture to working poster aided with the design of lifting equipment.
This is due to involvement of heavy lifting task although the working posture is improved. There are
many causes that can contribute to ergonomic injuries including muscle pulls, wrist injuries, back
sprains, elbow injuries, spinal injuries and other related injury [13]. Some of the causes are
incompatible weightiness of loads, awkward body postures, high frequency of materials to be lifted
and long durations needed for the lifting activities, inadequate handhold and environmental factors.
5. Conclusion
The main idea of this study is to investigate and improve the ergonomics working postures of the
workers working in the warehouse which focused on the task related to manual lifting activities. The
current working body postures was analysed using CATIA V5 software application to identify
whether the working body postures to identify the possible areas of improvement that can be made to
reduce the ergonomic risk factor and to reduce the risk of musculoskeletal disorder among the
workers. From the RULA analysis by the CATIA V5, even though the posture of the workers is
improved by changing the posture, the score is still 7 and its convey a risk of getting ergonomic
injuries because of the load of the task is still heavy and repetitions of work still occurs. However,
when a design of helping device is added into the working environment, the score of RULA is
decreases from 7 to 2. Thus, proved that the suggested working posture and helping device are
required in order to reduce the risk of getting ergonomic injuries.
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[4] Harry C 2002 Constant Force Technology (Trapp Road: St. Paul)
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International Technical Postgraduate Conference IOP Publishing
IOP Conf. Series: Materials Science and Engineering 210 (2017) 012079 doi:10.1088/1757-899X/210/1/012079
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[5] Middlesworth M 2007 A Step-by-Step Guide: Rapid Upper Limb Assessment (RULA)
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