Design of manual milling operation workstation for product dimensional accuracy and safe posture

Ng, Qi Mun (2016) Design of manual milling operation workstation for product dimensional accuracy and safe posture. Project Report. Universiti Teknikal Malaysia Melaka, Melaka, Malaysia. (Submitted)

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Abstract

In the economic crisis, the small and medium enterprises (SMEs) is trying to drive their business to profit based rather than safety, health and welfare of workers. Manual milling operation is widely applied in manufacturing industries under the SMEs. This operation is a precise task that requires the operators to pay high concentration to ensure the work piece being milled is accurate. However, the operators are exposed to various risk factors such as excessive vibration and noise, unclear machine gauge display, inappropriate working height, prolonged working hours, poor workplace ventilation and inadequate lighting level at the workstation while performing manual milling operation. The aim of this study is to redesign the existing manual milling operation workstation. This study applied interview, workplace observation, literature review and questionnaires survey among 20 workers in a medium sized machining company to determine risk factors associated with the manual milling operation. The risk factor which relate to non-neutral work posture was analysed by Rapid Upper Limb Assessment (RULA). This study explored the optimum manual milling workstation design through an experimental work using full factorial design of Design of Experiment (DoE). Additionally the operators’ requirements regarding manual milling workstation were captured using questionnaire survey and then transform to House of Quality (HOQ). Furthermore, five concepts of improved design of the workstation were sketched. They were screened through Pugh selection method based on practicability and cost effectiveness. Cost and benefit analysis (CBA) was used to evaluate the cost effectiveness of the screened concepts so that the final design also able to meet the entrepreneurial requirement. This study concluded that the new design of the workstation has improved the work posture and products quality. This study suggested that further investigation on excessive noise and vibration should be considered in the future research.

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