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DESIGN AND ANALYSIS ERGONOMICS WORKSTATION IN STAMPING

INDUSTRY

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 International Symposium on Research in Innovation and Sustainability 2014 (ISoRIS ’14) 15-16 October 2014, Malacca, Malaysia

DESIGN AND ANALYSIS ERGONOMICS WORKSTATION IN

STAMPING INDUSTRY
Seri Rahayu K, Mohammad Firdaus A and Norhidayah H.
Faculty of Manufacturing Engineering, Universiti Teknikal Malaysia Melaka,
Durian Tunggal, 76100 Melaka, Malaysia
Email: seri@utem.edu.my;

ABSTRACT
Nowadays, in manufacturing industries field the competition are more intense and more
competitor try won the heart of their customers. Hence, the demands for the product increase and the
company need to fulfill the demand. As the demands increases, the company should produce more
product than usual. In the same time the welfare and health of the workers should be consider. Some
factors such as workstation design should taken into consideration in order to increase the
productivity and at the same time protect workers from any hazard, injuries and health problem such
as Musculoskeletal Disorder (MSD). Therefore, the workstations need to be redesign by applying the
ergonomics principles to reduce the risks of MSD. In order to improve and redesign workstation,
Rapid Upper Limb Assessment (RULA) Analysis that available in CATIA software is used to analyze
and evaluate the working posture of the workers. The anthropometry of the workers and the
workspace design measurement data were used in RULA Analysis. The RULA scores and action level
is determined to indicates the working posture. Besides, the assessment of manual lifting – National
Institute for Occupational Safety and Health (NIOSH) Approach is used to recognized and addressed
the problem of work related back injuries and has formulated the equation for lifting tasks. The
productivity of the company before and after improvement is calculated using mathematical
equations. After redesign the workstation, the RULA scores of the worker’s working postures
improved.

KEYWORDS: Musculoskeletal Disorder (MSD), Ergonomics Principles, Rapid Upper Limb

Disorder Assessment (RULA), National Institute for Occupational Safety and Health (NIOSH),
Working Posture.

1.0 INTRODUCTION (12PT TIMES NEW ROMAN ALLCAPS)

In stamping industry, ergonomics principles and ergonomics workstation is the most
importance things to consider by the worker and company. That is because; ergonomics can
help in preventing workers from any injuries and unhealthy condition. Besides, ergonomics
can improve productivity and increase performance and quality of the product. Ergonomics
means the science of fitting the workplace conditions and job demands to the capabilities of
the working population. Besides, ergonomics also can be defined as a science of design [1&
2]. The ergonomics aims to design appliances, technical system and tasks in such way as to
improve the safety of human, health, comfort and performances. The main focus of this study
is to design and analyze ergonomic workstation for stamping industry. Hence, this study
takes place at one stamping manufacturing in Malaysia. According to the report issue by the
stamping manufacturing engineers, the laser cutting machine line had many problems
regarding to ergonomics problems. The workers complain that they experience fatigue and
pains at certain area of the body especially at the lower back of the body. These affect will
lead to musculoskeletal disorder (MSDs). The musculoskeletal system is very important to
move the body part as it is made up of the soft tissue and bones in the human body. The
damage of the tissue or the injuries of musculoskeletal system will cause the workers to
experience back pain that leads to MSD. Previous research studied that musculoskeletal
disorders (MSDs) attributed to work include a group of conditions that involve the nerves,

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 International Symposium on Research in Innovation and Sustainability 2014 (ISoRIS ’14) 15-16 October 2014, Malacca, Malaysia

tendons, muscles, and supporting structures of the body such as inter vertebral discs
[3,4,5&6]. In metal stamping industry, almost all the jobs are performed in standing position
and this can lead to muscle fatigue. According to Isa Halim et al., (2012), when workers are
performing jobs in prolonged standing, static contraction occurred particularly in their back
and legs, thus resulted to a diminished function of calf muscle [8 &7]. The data has been
taken about three days using same workers. This study used the analysis working posture
using the Rapid Upper Limb Assessment (RULA) to further investigatee the working posture
of the workers.

2.0 METHODOLOGY
The sample for this project will be the workers who work at Laser Cutting Machine 1.
These workers were chosen as the project respondent due to these processes involved
repetitive task higher than other process. Moreover, these processes and workstations
experienced a lot of ergonomic problem due to awkward body posture that can contribute to
musculoskeletal disorder (MSD) and health problem. This workstation is conducted by two
workers. In this study, the company visit, observation, questionnaire on workstation design
and open interview, has been used to collecting the data. The anthropometry and measuring
tape were used to measure the anthropometric of the workers while undertaken the tasks. The
data was used for RULA Analysis. The picture of the postures was taken and converted using
Computer Aided Three-dimensional Interactive Application (CATIA) software in order to
conducted RULA Analysis. The RULA Analysis was conducted for existing workstation
design and after redesign of the workstation. The bad posture of the workers during
performing the task was analyzed and any areas of improvement are identified. The RULA
score for each posture was discussed. The workstation of the Laser Cutting Machine was
redesigned to improve the posture of the workers and indirectly reduced the RULA score.
Besides, the recommended weight limit (RWL) that has been formulated by NIOSH is
determined whether for a specific task which is worker could perform for a specified period
without an increased of low back pain. The productivity of the company also calculated to
validate the improvement and to investigate the relationship between the ergonomics posture
with productivity.

3.0 RESULT AND DICUSSION

Figure 1 and Figure. 2 shows the worst worker working postures while performing the task
in Laser Cutting Machine 1.The pictures then converted to CATIA software for RULA
analysis as shown in Fig. 3. For the posture A, this posture may lead to Musculoskeletal
Disorder (MSD). In these postures, the workers have to bend their body to reach and put the
part on the pallet. This activity repeated frequently for eight hours period of time. The design
of the pallet should be taken into consideration in designing proper workstation. Fig. 4 shows
the final RULA score that prove the workers in this workstation were suffering pain while
performing tasks. The final score indicates that the posture needs immediate investigation and
changes.

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International Symposium on Research in Innovation and Sustainability 2014 (ISoRIS ’14) 15-16 October 2014, Malacca, Malaysia

Figure 1: Worst worker working posture (Posture A)

Figure 2: Body posture of the worker while performing task (Posture B)

Posture B

Posture A

Figure 3: The postures of the worker while performing task at Laser Cutting Machine 1

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 International Symposium on Research in Innovation and Sustainability 2014 (ISoRIS ’14) 15-16 October 2014, Malacca, Malaysia

Figure.4: The final score of the Posture A

Figure 5: The final score of the Posture B

For the posture b, the workers had to handle two parts which is finish part and scrap part. Figure. 5
shows the posture b having the final score of six. This score indicates that investigation and changes
required soon for this postures. The workers need to bend their body to put the parts on the pallet. The
workers have to hold two parts simultaneously. The right hand of the workers holds the finish part
while another hand holds the scrap part. On the left side, the workers need to bend backward their
hand to holds the scrap. On the right side, the workers need to bend their legs to lower their body in
order to reach the part. The workers have to fully stretch their hand to hold the finish part. The
designer of the workstation should consider the height of the pallet. So, the workers do not have to
bend their body to reach the parts.

Based on the RULA analysis of the existing workstation, all postures has highest final score and
need further investigation and immediate changes. It is means that, the worker at all workstations
undergone the awkward and wrong posture while handling the tasks. The existing workstations were
redesign according the ergonomics principles using the CATIA software. In laser cutting machine 1
workstation, there are two bad postures which is Posture A and Posture B. Both body postures of the
workers are affected by the design of the pallet. The height of the pallet is too lower and the workers
have to bend their body to reach the parts. The pallet design was improved by added the hydraulic

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 International Symposium on Research in Innovation and Sustainability 2014 (ISoRIS ’14) 15-16 October 2014, Malacca, Malaysia

lifting table as shown in Figure 6. The pallet was put on the hydraulic lifting table as this table can be
adjusted according to the required height.

Posture A Posture B

Figure 6: The posture of the workers while performing task (Posture A and Posture B) after
improvement

Based on the RULA analysis of the existing workstation, all postures has highest final score and
need further investigation and immediate changes. It is means that, the worker at all workstations
undergone the awkward and wrong posture while handling the tasks. The existing workstations were
redesign according the ergonomics principles using the CATIA software. In laser cutting machine 1
workstation, there are two bad postures which is Posture A and Posture B. Both body postures of the
workers are affected by the design of the pallet. The height of the pallet is too lower and the workers
have to bend their body to reach the parts. The pallet design was improved by added the hydraulic
lifting table as shown in Figure 6. The pallet was put on the hydraulic lifting table as this table can be
adjusted according to the required height.

The height hydraulic lifting table can be adjusted according to the required height. Based on the
guidelines listed by International Labour Organization (2012), the work surface should be adjustable
for workers of different heights and for different job tasks [9]. The new postures are analyzed and the
results are shown in Fig. 7. The final score is three which mean the further investigation is needed and
changes may be required. However, it shown that the final score has been reduced to three compared
than the existing postures which is final score of seven. Besides, the workers do not have to bend their
body while performing task. This can reduce the risk of back pain and musculoskeletal disorder
(MSD).

The same improvement also been applied to posture B. The pallet is put over the hydraulic lifting
table so the height of the pallet can be adjusted. The workers do not have to bend or stoop to reach the
parts. As mentioned before, the workers required to hold to parts; finish part and scrap part. The left
side of the body holds or carries the finish part while the right side carry the scrap part

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 International Symposium on Research in Innovation and Sustainability 2014 (ISoRIS ’14) 15-16 October 2014, Malacca, Malaysia

Figure 7: The new design of pallet and final score of the Posture A

Figure 8: The final score of the Posture B after improvement

Figure. 8 shows that the final score is four for the posture B. The final score improved from six
to four. This final score indicates that the posture needs further investigation and the changes may be
required. The red area in this posture is only at the forearm of the workers. This happens because the
distance of the reach is too far. According to International Labour Organization’s guidelines, in doing
the job tasks, the workers should not have to reach [9]. Therefore, the work should be performed (20
to 30 centimeters) in front of the body. The redesign of the workstation enables the workers to hold or
carry the scrap part without bending or twisting back their upper arm and their upper arm close to the
side. According to guidelines when performing standing work provided by International Labour
Organization (2012), the workers should be able to work with their upper arms at their sides and
without excessive bending or twisting of the back [4]. Furthermore, the workers should avoid carrying
loads with one hand as when only one hand is used to carry a load; the body is subjected to
mechanical stress.

The recommended weight limit (RWL) is then calculated to specify whether the load
sustained by the workers is appropriate or increase the risk of injury. The RWL is calculated
using this equation:

RWL = LC x HM x VM x DM x AM x FM x CM
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 International Symposium on Research in Innovation and Sustainability 2014 (ISoRIS ’14) 15-16 October 2014, Malacca, Malaysia

Where LC = load constant of 23kg

HM = horizontal multiplier = 25/H
VM = vertical multiplier = 1- (0.003| V - 75|)
DM = distance multiplier = 0.82 + (4.5/D)
AM = asymmetric multiplier = 1 – 0.0032A
FM = frequency multiplier (from Table 4.4)
CM = coupling multiplier (from Table 4.5)

The value of RWL is used to find the index for lifting. The ratio between the load actually
lifted and the RWL is known as the lifting index:

LI = L/RWL

Where L = Actual Weight

RWL = Recommended Weight Limit

The lifting index value will give a different meaning. If the index is less than 1 indicates that
not to increase the risk of injury. While if the index is equal or more than 3 indicates that
increase the risk of injury.

From the calculation of lifting index, the lifting index is greater than three as the final lifting
index is 24. Hence, it can be concluded that, the workers at this workstation will be at
increased risk of injury. The further action should be taken and the task should be redesigned.

4. CONCLUSION

The project background, problem statement, objectives of the project, scope and
limitations, project benefits, as well as project report structure have been outlined and
expanded in this study report. The main idea of this study was to design and analysis the
ergonomics workstation at stamping industry which focused on laser cutting machine line.
The existing workstation was designed and analyzed using CATIA software and RULA
Analysis for identify the possible areas of improvement at new workstation that designed to
reduce the several bad postures and reduce the risk of MSD among the workers. All the
objectives of the study have been achieved successfully. As a conclusion, the ergonomic in
industry need to pay more attention due to safety and health of the worker is depending on it.
Ergonomic problem will cause the operator either fast or slow effect. By considering the
ergonomic at workplace, the productivity will increase as well as improve the performance of
the company.

ACKNOWLEDGMENT
The authors would like to acknowledge the Ministry of Higher Education of Malaysia,
the Universiti Teknikal Malaysia Melaka (UTeM. Special thank also goes to Miyazu
Malaysia Sdn. Bhd. (MMSB) for the permission and opportunity to facilitate a fruitful
research.

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 International Symposium on Research in Innovation and Sustainability 2014 (ISoRIS ’14) 15-16 October 2014, Malacca, Malaysia

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