Redesign of polar cutting workstation in paper cups manufacturing industry using ergonomics approach

Kee, Kai Hung (2016) Redesign of polar cutting workstation in paper cups manufacturing industry using ergonomics approach. Project Report. Universiti Teknikal Malaysia Melaka, Melaka, Malaysia. (Submitted)

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Abstract

Manufacturing industry plays a significant role in the development of Malaysia. Paper cups manufacturing industry is one of the food packaging industry that deal with high demands on productivity and quality. This study focuses on the polar cutting workstation in a paper cups manufacturing company. In the existing workstation, the operator has to perform the polar cutting process in unsafe working postures. As a consequence, those manual material handling involved in the polar cutting process can contribute to the ergonomics health problem to the operator. The aim of this study is to redesign the polar cutting workstation in order to improve the manual lifting task by using an ergonomics approach. This study applied the observation-based methods and Quality Function Deployment (QFD) to redesign the existing polar cutting workstation. This study conducted the Rapid Upper Limb Assessment (RULA) analysis and NIOSH Lifting Equation analysis were used to measure the effectiveness of the redesigned polar cutting workstation. This study has shown the redesigned workstation able to improve the RULA score from 6 to 3 for the manual lifting tasks. Besides, the Lifting Index value is reduced from 1.44 to 0.70 and 2.02 to 0.67 for the origin and destination respectively. This study concluded that the redesigned workstation proposed has significant improvement in working posture and manual lifting task. For future work, this study suggests that the administrative control should be implemented in the company to further improve the product quality.

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