REVIEW SCIENTIFIC PAPER

LOW-COST ERGONOMICS SOLUTION FOR SAFE WORK POSTURE AT

CONVENTIONAL MILLING MACHINE

Muhammad Syamil
Mohammad Faris Izzudin Bin Mohd Zahari (060126)
Mirza
Table of Contents

1. INTRODUCTION .............................................................................................. 3
2. PROBLEM STATEMENT................................................................................ 4
3. HOW THE AUTHORS RECTIFY THE PROBLEM .................................... 4
4. LITERATURE REVIEW .................................................................................. 6
5. METHODOLOGY ............................................................................................. 8
6. ALTERNATIVE SOLUTION .......................................................................... 9
6.1. Engineering Controls (make a physical alteration to the workplace that
avoids or minimises the risk of injury on the work) ........................................... 9
6.2. Controls on administrative and work practices ......................................... 10
6.3. Training ...................................................................................................... 10
 1. INTRODUCTION
Milling is the process of removing metal from a surface. A spinning multipoint cutter
mounted on the milling machine's arbour removes metal during milling operations.
Milling machines cut away unneeded material from an item to create a variety of
features. The column, saddle, base, table, knee, arbour, over-arm, and spindle are the
essential components of a milling machine. Certain features of the milling process,
such as the workpiece, fixture, and cutter required by the milling machine, play a
critical role. The work was kept in a fixture that was mounted to a milling machine
table. A milling machine's table may move in three directions: across, vertically, and
longitudinally. We knew the milling machine required a lot of movement because of
this.

The major assets of pioneering plants in various industrial areas are productivity,
product quality, and innovation. These notions need firms' efficient use of human
resources, which leads to increased earnings on both a material and human level
(Cavassa, 2008). Human resources are one of the most significant components of an
enterprise's industrial production activities. It is critical to examine the environment
or workspace in which the operators conduct their activities in order to maximise
efficiency and improve quality. This demonstrates the value placed on ergonomics in
terms of increased productivity. It is a strategy targeted at increasing operator quality
and comfort (Rivero, Rodrguez, Pérez, Mar, & Juárez, 2015). For production firms,
ergonomic goals to enhance efficiency and quality include the design and arrangement
of an appropriate workstation. As a result, it's critical to establish a proper interaction
between environmental aspects like illumination, noise, and temperature, as well as
working conditions like the operator's developed effort, posture, operation
repeatability, and the tool employed (Cavassa, 2008). Human resources and labour
expenses are currently having a significant impact on manufacturing activity; as a
result, it is critical to improve and facilitate working conditions in order to maximise
productivity.
By that we support the scheme suggested by author that solution is needed for workers
to have a safe and sound working experience.

2. PROBLEM STATEMENT

The work stations investigated in this study use a milling machine, which allows for
the execution of multiple machine techniques on metallic or plastic parts, resulting in
high-precision designs that fulfil technical criteria. According to the author, the
challenge of managing milling machines leads to non-neutral work postures, which
can lead to back pain and poor machining quality. As previously stated, "moderate"
pain manifests mostly in the shoulders, lower back, and popliteal region, with
"unbearable" pain manifesting in the middle of the back, hand, and arm. As a result,
when this equipment is used, there is a lot of pain and discomfort among the workers.
Stressful body postures and repeated hand and arm movements were also seen.

3. HOW THE AUTHORS RECTIFY THE PROBLEM

Each area of work must undoubtedly include some amount of danger (Risk).
Nevertheless, in every risk, management should manage with each other in a secure
environment so as not to risk other employees.

Muscular strain builds up and can lead to disease later in life. Difficult, confined,
uneven, repetitive, and protracted postures can strain muscles and surpass appropriate
pressure threshold, resulting in tiredness or unbalance and injury. Maintaining a static
position for extended durations compress the veins and capillaries in the muscles,
resulting in micro lysis owing to a lack of oxygen consumption and feeding. Because
of tissue problems, all these elements can produce unbalance, weariness, tension, and
pain. Muscular, tendons, and ligaments are the tissues that are harmed because of poor
postures. Nerve endings can be harmed because of compressibility or hypoxia.
Furthermore, the joints and tissues can be harmed by increased loads and stresses over
time. Several epidemiology researchers have provided evidence that posture is
connected to back, shoulder, and wrist musculoskeletal diseases, according to the
Occupational Safety and Health Administration and Health (NIOSH) in the United
States. A survey done by Magnusson and Pope also found that poor posture is linked
to difficulties with the neck, shoulders, arms, hips, and knees. As a result, there is a
link between working posture and musculoskeletal conditions.

The following desire is similarly addressed in this manner. Wear safety eyewear that
has been CSA-certified. Wear any other personal protective equipment that is required
(such as shoes or hearing protection). Ensure that all machines have a start/stop button
that the operator can easily access. Ensure that all machinery have a stop button in
case of an emergency (e-stop). Before cutting, ensure that the workpiece and cutter
are securely placed. Check that the work is properly installed. Place the work in a vice
that is attached or magnetically secured to the table. To make modifications, use the
appropriate hand tools. For further information, see Hand Tools. To avoid cutting
while handling the milling cutter, wrap it with a cloth. To avoid harming your hands,
move the table as far away from the cutter as possible while preparing for work. First,
the largest surface range. Hands, brushes, and rags should be kept away from whirling
milling cutters. Remove the clippings with a vacuum, brush, or rake only after the
cutter has stopped moving. Change the cutting compound on a regular basis. Check
that the cutter is properly sharpened and in good working order. Clear debris, tools,
and supplies from work areas. While cleaning the machine, remove the cutting tool
from the spindle. Make sure the area around the grinder is clean and free of oil and
grease. When transferring heavy work to or from the milling machine, use lifting
equipment as needed. For more information, see Material Handling. Before changing
the cutter, be sure the power is turned off. Always keep your eyes on the machine.

As a result, the solution is how to tackle the challenges described. This material has
also been improved to provide the reading audience with a better comprehension. As
a result, use wisdom and high responsibility to guarantee that every issue is resolved
in a quality and safe manner and in accordance with the working conditions that have
been established.

4. LITERATURE REVIEW

The documentation for doing a literature review is complex and challenging, yet a few
of organizations had performed well. Several meta-analyses on low-cost ergonomic
solutions for safe work in conventional manufacturing have been discovered and
enhanced to operate best with members in the group. The thesis made the following
statement, presents the summary of findings obtained.

There has been few research on the subject. Among them is research on health & safety
robots undertaken by Sugimoto (1987) for the Japanese Ministry of Employment.
Following that, Chan, and Courtney (2001) deliver an analysis of work areas with
hybrid manufacturing systems in which humans and robots engage, but also where
ergonomic and safety factors have been overlooked, and Vieira and Kumar (2007)
inform about work-related lower back pathologies in CNC employees and
metalworkers. Manufacturing equipment injuries have been the most common,
according to McEwan (1998) and Yu et al. (1999).

According to Karnowski and Salvendy, workstations that use Advanced

Manufacturing Technology suffer from a lack of attention in terms of health and safety
(1994, 2005). According to Ayres and Miller (1985), Masterson (1987), Zymology
and Duda, the health and safety components of AMT systems have been neglected in
the equipment evaluation and selection process, making it difficult to determine the
magnitude of its potential influence in this field (1992). This is due to lack of
knowledge or incomplete information. Also, like Nicolaisen (1985), Karnowski et al.
(1988), Karnowski and Salvendi (1994) (2005), Sugimoto and Kawaguchi (1985)
pointed out, the high number of AMT incidents is not recorded and reported, making
it impossible to trace these events to such technologies.
So, the outcome of this research that we simplified from a few of the substance of the
issue that is desired is this literature review. Some of those discovered are covered in
the resulting literature review. Several issues linked with the provided theme have
already been addressed during the drafting of this literature research.
 5. METHODOLOGY

The total success of an ergonomic procedure depends on company's strong

commitment. OSHA recommends that foundries create specific goals and objectives
for the hazardous process throughout the stage of development, communicate them
with their employees, and delegate tasks to authorized employees. Manager should
encourage and assist in the formation of a combined employee ergonomic team,
hold frequent committee meetings, and respond to workers' complaints in a
reasonable timeframe. The essence of an effective ergonomic procedure is a
participative ergonomic approach, in which workers are closely engaged in worksite
assessments, solution creation, and execution.

Rather than being considered as a one-time effort, an ergonomic procedure should be

viewed as a continuous function that is integrated into the facility's daily operations,
similar to how safety and production issues are addressed. Worker participation in the
ergonomic process and choices that influence their safety and health should be
aggressively encouraged by management. Employers should also clearly identify
processes that encourage employees to bring their problems to management's attention
and respond to employee input. Other workplace practices, as well as an ergonomic
approach, have been effectively integrated into the operations of many foundries. One
example is the “lean manufacturing” strategy, which focuses on providing “the right
material, to the right place, at the right time, in a proper manner”. These tactics aim to
eliminate non-value-added processes in the production process, such as "wasted
walking" or "wasted motion" when picking up parts. Because ergonomic concepts help
detect and control activities that hinder from employee outcomes, they are a suitable
fit with these tactics.
 6. ALTERNATIVE SOLUTION

Many companies have successfully adopted ergonomic solutions in their premises

to reduce the risk of MSD injuries among their employees. Modifying old
infrastructure, changing labour techniques, and purchasing new tools or other
gadgets to aid with the production chain have all been part of these interventions.
Physical constraints were minimised, superfluous movements were removed, injury
rates and associated workers' compensation expenses were minimized, and staff
turnover was decreased as a result of these adjustments. Productivity level and
production have grown in several circumstances. Problems are frequently solved
with simple, low-cost remedies. Use the data on this page to see what has worked
in the past for others in your sector or in other industries.

6.1. Engineering Controls (make a physical alteration to the workplace that

avoids or minimises the risk of injury on the work)

 To reduce force exertion, use a gadget to lift and reposition large things.

 To minimize force strain, reduce the weight of a load.

 Reposition a work table to eliminate a wide reach and allow for neutral
postures while working.
 Diverging conveyors off a main line can reduce repeated work.

 To avoid excessive bending or reaching, install diverters on conveyors to

guide items toward the worker.
 Tools should be redesigned to allow for neutral postures.
6.2. Controls on administrative and work practices

 To reduce force exertion, just two individuals should lift heavy goods at a time.

 Set up methods for workers to be rotated away from jobs to reduce the
amount of time they are exposed to constant exertion, repetitive movements,
and poor posture. Create a method for employees to rotate between jobs that
require multiple muscle groups.
 Use and operate pneumatic and power tools correctly

6.3. Training

Training alone will not enhance your ergonomics. Instead, it can be used in
conjunction with any modifications made to the workplace. Workers require
training and hands-on experience with new tools, gear, or work procedures in
order to ensure that they have the essential abilities to operate safely. When
training is interactive and fully incorporates workers, it is most effective.
Following are a few training ideas based on principles of learning:

 When additional features, equipment, or processes are presented to the

workforce, provide hands-on practise.
 Use a variety of visual aids (e.g., photographs, charts, and films) to
demonstrate actual work duties.
 Hold talks and problem-solving sessions in small groups.

 Allow plenty of time for workers to ask questions.