Ergonomics intervention to improve plastic roll handling process at production area in plastic manufacturing industry

Lai, Yan Ling (2017) Ergonomics intervention to improve plastic roll handling process at production area in plastic manufacturing industry. Project Report. Universiti Teknikal Malaysia Melaka, Melaka, Malaysia. (Submitted)

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Abstract

Manufacturing industries play an important role in the economy of Malaysia. One of the manufacturing industries is plastic manufacturing industry. In this plastic manufacturing industry, the product which is in the form of plastic rolls are heavy and large. Basically, the transportation of plastic rolls from one location to another is carried out manually by the operators by using substandard assistive device. Performing tasks without proper technique and assistive device leads to ergonomics risk factors which may causes occupational health such as low back pain and musculoskeletal disorders (MSD). The aim of this study is to redesign the existing plastic roll handling device to ease the plastic roll handling process. The ergonomics issues related to manual plastic rolls handling tasks were determined via workplace observation and questionnaire survey. The ergonomics risk factors at the existing plastic rolls handling process were analysed by using Rapid Upper Limb Assessment (RULA) and Push-Pull Analysis. In order to redesign the existing plastic roll handling device to improve productivity and occupational health of workers, customer requirements were translated into technical requirements in House of Quality (HOQ). Furthermore, the concepts of the improved design of the plastic roll handling device were gathered and screened through concept selection method to select the best conceptual design based on the practicability and low manufacturing cost. Cost and benefit analysis (CBA) was used to analyse the effectiveness of the selected design in terms of cost saving and return on investment in order to meet the entrepreneurial requirement. This study concluded that the new design of the plastic roll handling device is able to improve plastic roll handling process with the RULA score improvement. This study suggests that the real fabrication and application should be implemented in the industry in order to improve the work posture and reduce the exertion of excessive force.

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