UNIKL MSI

SCB48304 - AUTOMOTIVE ERGONOMICS

ASSIGNMENT 4:
CASE STUDY ASSIGMENT

N NAMA NO.ID
O
1 MUHAMMAD ZAHID ADZEEM BIN MOHD ZIN 54211116033
2 ZULLFIRMAN HAMBALI BIN ZULKAFFLE 54211116122
3 MUHAMMAD MUIZZUDDIN BIN MOHD NIZAM 54211116132
4 MUHAMMAD HAKIM BIN HISHAM 54211116148
5 MUHAMMAD FAIZ DANIAL BIN ADENAN 54211116066

PREPARED FOR:

MR KHAIRUL AKMAL BIN SHAMSUDDIN

CASE STUDY EXERCISE

 Discuss and give the solutions of all the case studies below:

2.0 WORKERS WALK LONG DISTANCES

Problem

• Workers spend too much time walking and searching for materials.

• Picking sheets give no direction for efficient picking routes.

• Duplicate material stored throughout facility.

Solution:

Storage solutions play an important part in implementing waste elimination, one of

the key pillars of 5S. Safety and good housekeeping principles particularly are
important when it comes to storage. An effective storage solution gives the ability to
store many items close to the operation, and a visual labeling system makes it easy,
quick and safe to store, find and retrieve items. The ability to pull a drawer or shelf all
the way out to retrieve items keeps employees from placing themselves in an unsafe
position and environment, while storage solutions free up floor space, eliminating
tripping hazards and clutter and improve visual management. Systems should be set
up so everything has a place and readily is available when needed. Everything should
be labeled and identified. Local storage minimizes travel time, and adjustable storage
and workbenches make it easier to adapt to the differing needs of individual
employees.

A clean, well-organized and safe work environment is, of course, an efficient and
productive work environment. A less obvious, but still important, aspect of lean is that
it gets the employees involved throughout the process, engaging and challenging best
practices, encouraging the employees to have a real sense of involvement and to work
hard to maintain all the effort the team has invested.

Floor Markings
Floor markings have proven to be one of the most effective ways to improve safety
and increase efficiency within a facility. There are many ways these types of markings
can be used to benefit the facility, all of which will reduce or eliminate some type of
waste. Floor marking tape can be used to mark off aisle ways so drivers of high-lows
and other vehicles know how close to the edge they are at any given time. Arrows can
be used to indicate which way traffic should flow so other vehicles don't get in the
way or cause an accident. Floor marking tape and floor marking symbols can also
identify emergency exits, the routes of production, and much more. Since this type of
floor marking is inexpensive and effective, it is a good option for 5S.

Some examples of how a facility can improve organization include the following:
  Tool Organizers - Options like pegboards and shadow boards make sure
every tool in a shop has a set place. Employees will know exactly where to go
to find what they need and where it needs to be put when they have finished
the task.

 Parking Labels - Identifying where particular vehicles should be parked when

not in use will help ensure they are there when needed. For electric vehicles,
this can also ensure they are being charged when not in use so they are always
ready to go. Using floor marking tape is a great way to facilitate this type of
organization.

 Drawer Labels - When items are kept in drawers or cabinets, having them
labelled from the outside is an effective way to speed up the process of getting
what is needed. Rather than having to pull out each drawer and look through,
employees can just locate the one that contains what they need and look there.

 Relocating Machines - Depending on the size of the facility and the machines
in use, this can be a significant project, but it may be worth the effort. Moving
machines around so production flows from one machine to the next with as
little wasted motion as possible is a great way to reduce waste.

3.0 WORKERS IN HOSTILE ENVIRONMENTS

Problem

• Material is stored in refrigerated or freezer environments.

• Manufacturing processes generate excessive heat, noise, and/or particulates.

• Workers must handle hazardous materials and Workers must handle heavy loads.

• Excessive forklift truck traffic creates a hazardous work area.

• Companies must meet stringent OSHA requirements for worker safety.

Solution:

Material is stored in refrigerated or freezer environments.

Certain refrigerator/freezer units are designed for the safe storage of flammable
materials, and to prevent potentially injurious explosions in your lab. These units have
special protections to prevent ignition of flammable vapours. For example, the light
switch, defrost feature, and thermostat inside the storage compartment have been
removed or relocated outside the box. This is critical, since flammable vapours
coupled with an ignition source could result in a explosion. Before purchasing a new
refrigerator/freezer, or using an existing one, consider whether chemicals will be used
for storage in this unit.

There are two types of refrigerator/freezer models that should be considered,

depending on the type of hazardous material the unit will store.

I. FLAMMABLE MATERIAL STORAGE REFRIGERATORS/FREEZERS:

For further information contact EH&S Laboratory Safety Specialist at X4899 All
refrigerator/freezer purchases and modifications on campus must be pre-approved by
EH&S at X8243. In addition, all approved refrigerator/freezer units storing
flammable materials must be labelled with signage reading, “Approved For
Chemical Storage, No Food Storage”. All refrigerator/freezer units in labs, which are
not approved for storage of flammable materials must be affixed with signage
reading, “Explosion Hazard”.

Workers must handle hazardous materials and handle heavy loads.

 Exposure to chemicals commonly used in workplaces can lead to a variety of short-
and long-term health effects such as poisoning, skin rashes and disorders of the lung,
kidney and liver. A quarter of all Victorian employees regularly use hazardous
substances such as chemicals, flammable liquids and gases in their work. A hazardous
substance can take many forms, including gas, powder, liquid, solid or dust. The
product may be pure or diluted. Manufacturers and importers of hazardous substances
are legally obliged to include warning labels and Safety Data Sheets with their
products. This information offers advice on safe handling practices many industrial,
agricultural and medical organizations use hazardous substances. The degree of
hazard depends on the concentration of the chemical.

Common hazardous substances in the workplace include: 

 Acids

 caustic substances

 disinfectants

 glues

 heavy metals, including mercury, lead, cadmium and aluminium

 paint

 pesticides

 petroleum products

 Solvents.

Lifting heavy items is one of the leading causes of injury in the workplace. In 2001,
the Bureau of Labor Statistics reported that over 36 percent of injuries involving
missed workdays were the result of shoulder and back injuries. Overexertion and
cumulative trauma were the biggest factors in these injuries. Bending, followed by
twisting and turning, were the more commonly cited movements that caused back
injuries. Strains and sprains from lifting loads improperly or from carrying loads that
are either too large or too heavy are common hazards associated with manually
moving materials.
When employees use smart lifting practices, they are less likely to suffer from back
sprains, muscle pulls, wrist injuries, elbow injuries, spinal injuries, and other injuries
caused by lifting heavy objects. Please use this page to learn more about safe lifting
and material handling.

Excessive forklift truck traffic creates a hazardous work area.

What factors of work organization can contribute to forklift truck accident?

 Production factors such as speed or stress.

 Lack of proper tools, attachments and accessories.

 Improper assignment of forklifts and operators.

 Poor maintenance of forklifts.

 Age of forklifts.

 Lack of training or improper training of workers who have to operate forklift

trucks.

How can incidents with pedestrian be reduced or avoided?

 Separate the pedestrian and forklift traffic by creating designated walkways or

travel ways.

 Restrict people from entering areas where the forklift is operating. If not
possible, develop safe work procedures to protect workers when they must
enter areas where forklifts are operating.

 Keep a safe distance from the forklift whenever possible.

 Pedestrians should always let the driver know they are in the area. Make eye
contact with the driver to ensure your presence is known.

 Make sure the area is well lit and there are no obstructions.

 Be cautious near blind corners, doorways, and narrow aisles. Sound the
forklift horn at intersections.
Companies must meet stringent OSHA requirements for worker safety.

Under the OSH law, employers have a responsibility to provide a safe workplace.
This is a short summary of key employer responsibilities:

 Provide a workplace free from serious recognized hazards and comply with
standards, rules and regulations issued under the OSH Act.

 Examine workplace conditions to make sure they conform to

applicable OSHA standards.

 Make sure employees have and use safe tools and equipment and properly
maintain this equipment.

 Use colour codes, posters, labels or signs to warn employees of potential

hazards.

 Establish or update operating procedures and communicate them so that

employees follow safety and health requirements.

 Employers must provide safety training in a language and vocabulary workers

can understand.

 Employers with hazardous chemicals in the workplace must develop and

implement a written hazard communication program and train employees on
the hazards they are exposed to and proper precautions (and a copy of safety
data sheets must be readily available). See the OSHA page on Hazard
Communication.

 Provide medical examinations and training when required by OSHA

standards.
 4.0 SAFETY HAZARDS

Problem

• Companies must meet increasingly stringent OSHA requirements for worker

safety.

• Companies are often held liable for workplace accidents and injuries.

• Workers have to climb, bend, stoop, or stretch to access material.

• Workers must handle bulky or heavy loads.

• Material is stored in a hostile environment (i.e., -10º F freezer).

• Material must move at high speed.

Answer suggestions:

An ergonomic hazard is a physical factor within the environment that harms the
musculoskeletal system. Ergonomic hazards include themes such as repetitive
movement, manual handling, workplace/job/task design, uncomfortable workstation
height and poor body positioning.

Ergonomics is the study of how a workplace, the equipment used there and the work
environment itself can best be designed for comfort, efficiency, safety and
productivity. Often we can improve our levels of comfort and productivity with
relatively simple changes.

Ergonomic issues can be associated with a wide range of concerns including the
physical design of workstations, workspaces, the working environment, tools,
vehicles, computer programs and plant. It can also involve cognitive processes such as
those involved with workload, decision making, skilled performance and stress. There
are procedures for dealing with all these issues to make sure any difficulties are
addressed.
Many industries have successfully implemented ergonomic solutions in their facilities
as a way to address their workers' MSD injury risks. These interventions have
included modifying existing equipment, making changes in work practices and
purchasing new tools or other devices to assist in the production process. Making
these changes has reduced physical demands, eliminated unnecessary movements,
lowered injury rates and their associated workers' compensation costs, and reduced
employee turnover. In many cases, work efficiency and productivity have increased as
well. Simple, low-cost solutions are often available to solve problems. Use the
information on this page to see what has worked for others in your industry or in other
industries

To reduce the chance of injury, work tasks should be designed to limit exposure to
ergonomic risk factors. Engineering controls are the most desirable, where possible.
Administrative or work practice controls may be appropriate in some cases where
engineering controls cannot be implemented or when different procedures are needed
after implementation of the new engineering controls. Personal protection solutions
have only limited effectiveness when dealing with ergonomic hazards.
 Type of Control Workplace Examples

 Use a device to lift and reposition heavy objects to limit force

exertion.
 Reduce the weight of a load to limit force exertion.

Engineering Controls (implement  Reposition a work table to eliminate a long/excessive reach

physical change to the workplace, and enable working in neutral postures.

which eliminates/reduces the hazard on  Use diverging conveyors off a main line so that tasks are less

the job/task) repetitive.

 Install diverters on conveyors to direct materials toward the
worker to eliminate excessive leaning or reaching.
 Redesign tools to enable neutral postures.

 Require that heavy loads are only lifted by two people to limit
force exertion.
 Establish systems so workers are rotated away from tasks to
minimize the duration of continual exertion, repetitive
Administrative and Work Practice
motions, and awkward postures. Design a job rotation system
Controls 
in which employees rotate between jobs that use different

(establish efficient processes or muscle groups.

procedures)  Staff "floaters" to provide periodic breaks between scheduled

breaks.
 Properly use and maintain pneumatic and power tools.

 Use padding to reduce direct contact with hard, sharp, or

Personal
vibrating surfaces.
Protective Equipment   Wear good fitting thermal gloves to help with cold conditions
while maintaining the ability to grasp items easily.
(use protection to reduce exposure to
ergonomics-related risk factors)
5.0 EXCESSIVE NOISE LEVELS

Problem

• Sources of material handling noise:

 Conveyors (steel bins on steel rollers, chains, low-quality bearings) are

typically the noisiest component of a material handling system.
 Excessive forklift truck traffic.
 Rattling tow carts caused by uneven floor surface.

• Increased worker fatigue, reduced productivity.

• More difficult for workers to communicate, alert to safety hazards.

• Higher employee turnover.

• Noise forces supervisor offices to be located away from work areas.

Solution:

Exposure to noise in your work environment may cause a number of

physiological and psychological responses. Noise can:

 Cause hearing loss.

 Annoy and interfere with speech.

 Interfere with concentration and thought processes.

 Disturb sleep.

 Cause fatigue and aggression.

 Reduce immune response.

 Lead to heart disease.

High noise levels

High levels of noise may initially cause dull hearing and ringing in the ears. Regular
high level noise exposures will lead to loss of hearing and other adverse health
effects.

Low noise levels

Low levels of noise can interfere with activities or concentration and causes similar
stress and health effects as high level noise.

Exposure to excessive noise levels at the work place damages the hearing of
employees. In addition, noise may interfere with working efficiency and disturb
concentration, especially where work is highly skilled and decision taking. There are
several criteria for occupational noise, which take into account the allowable noise
energy for each frequency band. Noise induced loss occurs gradually due to high
noise exposure workers. There are three approaches that can be used.

Problem: Engineering controls for existing plant and workplaces:

Solution:

The need for noise control should be considered when deciding production methods
or processes and when the need to reduce noise exposure has been established.
Examples of engineering controls can include:

 Repairing loose and rotating parts, replacing worn bearings and gears and
regular maintenance.

 Adding noise barriers, noise enclosures, vibration isolation mountings,

laggings, mufflers and silencers where appropriate to reduce noise at source.

 Absorbing acoustic shock by providing wear-resistant rubber or plastic

coatings.
  Using conveyor belts rather than rollers.

 Using sound-absorbing material on floors, ceiling and/or walls to reduce the

sound level due to reverberation.

Problem: Administrative controls:

Solutions:

Should be used when it is not possible to reduce noise exposure through engineering
noise control measures. These include:

 Organizing schedules so that noisy work is done during a particular part of the
shift or when as few people as possible are present (Office hour).

 Notifying people in advance when noisy work is to be carried out so they can
limit their exposure to it.

 Limiting the time workers spend in noisy areas by moving them to quiet work
areas before their daily noise exposure levels are exceeded.

 Maintaining machines and equipment in good condition to reduce noise,

including the addition of noise mufflers, vibration isolators, or duct silencers.

 Purchasing new plant and equipment that produce less noise.

Problem: Personal hearing protectors:

Solutions:

A personal hearing protector can be worn to cover the ear and ear canal entrance, or
inserted in the ears of a person to protect their hearing. Personal hearing protectors
should be used when noise levels cannot be reduced by other control measures. Staff
at workplaces should be:

 Supplied with personal hearing protectors of correct rating and suitable for the
work conditions.

 Instructed in their correct use.

 Instructed to wear them when exposed to noise.

  Monitored to ensure they wear hearing protection.

6.0 MATERIAL HANLDING

Lifting heavy loads, twisting, turning, and bending can cause muscle strains and
sprains. For example, reaching at arm’s length to pick up a full case can stress the
back and shoulder muscles, especially if the person has to reach down often (refer fig.
9 below). This kind of repetitive stress might also irritate nerves in the shoulder.

Problems:
 The way to avoid material handling problems as above.

ANSWER:
Manual handling also involves any transporting or supporting of a load by one or
employees or moving a load. If not carried out ergonomically, manual handling
activities can lead to serious physical injury.

MINIMIZE SIGNIFICANT BODY MOTIONS

1. Eliminate the need to bend by :
Using lift tables, work dispensers and similar mechanical aids .Raising the
 work level to an appropriate height. Raising or lowering the worker and
providing all material at work level.

2. Reduce twisting motions :

Providing all material and tools in front of the worker. Using conveyors,
chutes, slides, lifts or turntables to change direction of material flow
.Improving the layout of the work area.
3. Reduce reaching out motion :
Providing tools and machine controls close to the worker to eliminate
horizontal reaches over 16 inches. Placing material, workplaces and other
heavy objects as close to the worker as possible. Allowing the object to be
kept close to the body.

EVALUATE OF STANDING AIDS:

 Footrests and footrails

 The footrests raised foot 250mm above the level of the floor and resulted in
a net posterior rotation of the pelvis of 4º- 6º

 Antifatigue mats

 Mats reduce the discomfort in the lower leg, feet and back.

 Compression Stocking

 The wearing compression stockings can reduce the swelling.

 Shoes

 Standing workers who choose to replace their high heeled to flat shoes
should expected less physical fatigue during a work shift and less fatigue-
related musculoskeletal pain.