the study on ergonomic performances based on workstation
TRANSCRIPT
INTERNATIONAL JOURNAL OF INTEGRATED ENGINEERING VOL. 12 NO. 5 (2020) 124-129
© Universiti Tun Hussein Onn Malaysia Publisher’s Office
IJIE
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The International
Journal of
Integrated
Engineering
ISSN : 2229-838X e-ISSN : 2600-7916
* Corresponding author email: [email protected] 124 2020 UTHM Publisher. All rights reserved.
penerbit.uthm.edu.my/ojs/index.php/ijie
Abstract: The paper discusses the dimensions of manual workstation in a semi-conductor industry and their effects
to the ergonomic performances. The workstation provided quality control activity where the worker need to manually
handle thousands of microchips and check their quality. Three dimensions were considered as workstation design
parameters, namely as scope distance, scope height and chair height. Three measured were considered as ergonomics
performances of the workstation, which were production cycle time, working posture and recommended weight limit.
The performances are measured by using Method Time Measurement, Raid Upper Limb Assessment method and
NIOSH recommended weight limit method respectively. The study was provided under a virtual manufacturing
software. All of the workstation’s components and the activities of the worker are modelled into Delmia V5 (Virtual
Ergonomics Solution) software. Design of Experiment (DEO) was conducted by using Design Expert Statistical
Software with Central Composite Design of Response Surface Methodology. Fifteen simulation experiments with
different dimensions of design parameters were conducted as suggested by the DEO method. The results showed
that production cycle time and working posture were affected by all of the design parameters. However, the weight
limitation was only affected by scope height and chair height. The study continued to find the dimensions that gave
the best ergonomic performance of the workstation.
Keywords: Workstation design, Ergonomics performances, Production Cycle Time, Working Posture and Weight
Limitation.
The Study on Ergonomic Performances Based on Workstation
Design Parameters using Virtual Manufacturing Tool Mohd. Iqbal1, Iskandar Hasanuddin1*, Azmi Bin Hassan2, Mohd Syafiq Mohd
Soufi3, Friesca Erwan1
1Department of Mechanical and Industrial Engineering, Faculty of Engineering,
Universitas Syiah Kuala, Jalan Syech Abdur Rauf, No 7, Darussalam, Banda Aceh, 23111, INDONESIA
2Electronic & Automation Section,
Universiti Kuala Lumpur, Malaysian Spanish Institute, Kulim Hi-Tech Park, 09000, Kulim, Kedah, MALAYSIA
3Linier Semi-Conductor Sdn Bhd, Malaysia, Kuala Lumpur, MALAYSIA
*Corresponding author
DOI: https://doi.org/10.30880/ijie.2020.12.05.015
Received 21 May 2020; Accepted 28 May 2020; Available online 30 June 2020
1. Introduction
In engineering field, ergonomics studies become more important from time to time due to many injuries have been
recorded at the workplace. In order to become high industrial and competitive country in the world, Industries should
preserve its human resources and make the occupational safety and health as their main priority towards the workers. The
occupational injuries caused by poor manual lifting techniques are a major occupational problem even in the highly
industrialized countries. Thus, the field of Occupational Safety and Health (OSH) plays an important role in the
engineering field to ensure the safety of workers at the workplace.
Mohd. Iqbal et al., International Journal of Integrated Engineering Vol. 12 No. 5 (2020) p. 124-129
125
Day by day, there will be new technology to increase the productivity. Thus, new work procedures need to be taken
by the workers to optimize the production in order to cope with the new technology. But there is almost no concern given
to the consequences for the workers for the implementation of these new work procedures.
In ergonomics, poor body posture leads to a serious problem. Tasks which performed in proper working posture and
frequent body movements would reduce the number of risks for musculoskeletal disorders [1]. A worker’s discomfort,
for example, due to body twisting while doing manual lifting puts unnecessary energy demands which by no means
contribute to the declination in worker’s productivity. In industry, workers should be provided with a manual guideline
on how to prevent critical or awkward posture [2, 3] due to inappropriate workstation’s designs and job tasks which lead
to workplace injury [1]. Assessing body posture can be done through manual assessment such as using Nordic
Musculoskeletal Symptom Survey or automatic systems such as a wireless and ambulatory posture monitoring system
which can monitors the movement of the human body and detects the change of the body postures [4]. In addition, apart
from body posture, workers need to have clear working procedures and working time, as well as suitable physical working
environment with the job performed in the working area thus minimize psychology effect experienced by the workers
while performing their tasks [5].
Applying ergonomics principles will enable workers to perform their tasks safely and efficiently. Therefore, it is
essential to carefully design a workstation by implementing the principles recommended in ergonomics. It is important
to study the effect of workstation design parameter on human performance, especially in manual working activity.
In industries, there are efforts to ensure that the workstation is safe for the workers. However, this ergonomics
principle has always been neglected by most of the engineering companies, especially in manufacturing industries. The
low level of implementation of ergonomics has close related to the occupational hazards [6]. In a Semiconductor industry,
there are many complaints received from the workers that they experienced back pain while doing their work in a long
period of time. This problem might affect their productivity to the company and also might affect their health. Many
researchers have mentioned about the importance of implementing ergonomics principle in the workplace. However,
there was a little study on the effect of different workstation design parameter on human performance in the manual
working task, specifically in semiconductor industry. Therefore, this study seeks to find out the best design on the current
workstation at a semiconductor industry.
The goal of this study is to improve the current workstation design of a semiconductor industry in order to improve
the performance and health of the workers. The objectives of the study are be listed as follow:
1. To examine the layout design on the current workstation 2. To study the effect of workstation design parameter on ergonomics performances (cycle time, working posture and
weight limitation)
3. To find the best design of the workstation based on optimum ergonomic performance.
2. Methods
Digital human model enables the study of product and process adaptation for people without any need of physical
prototypes, therefore reduce the time and costs [7]. The use of a virtual reality environment in ergonomics enables the
design evaluation conducted through virtual mock-ups, which is much less costly than traditional mock-ups. These virtual
manufacturing simulations provides industrial applications either in the design or in the manufacturing processes such as
to evaluate safety, operability or maintainability of a production line [6-8].
There are several types of CAD software that are available in the market. Some of these ergonomic software packages
includes Delmia V5, UGS’ Jack Software, ErgoIntelligence, Envision Ergo, ErgoEASER and SafeWork. This study used
Delmia V5 (Virtual Ergonomics Solution) software to model the workstation’s layout design and its activity then to study
the related ergonomic performances.
3. Result
The inspection workstation in the assembly line of a semiconductor industry in Malaysia were studied in this
research. Most of the assembly tasks were fully automatic but the considered inspection workstation, namely the 3rd opt
workstation provided manual inspection tasks. A worker provided the following three stages of the task:
1. Lifting – the worker lifted the “magazine” from the rack to the workstation 2. Inspection – the worker inspected (in static position) every unit of the product from the magazine using a microscope.
Each magazine had thousands of units depending on the lot size
3. Lowering – the worker lowered the magazine once the inspection has been completed.
After 8 hours of continuous working, the workers experienced the pain at their back and neck, and muscle stress at
their shoulders. Based on the interview and investigation of the workstation condition, a hypothesis was taken up that the
pain and stress were caused by the poor design of the workstation. The workers need to bend their back and neck too low
during the inspection and need to reach too far to the rack. However, lowering the rack and rising the table were not a
simply solution since the affects were not linier, the space constrains need to be considered and several related
performances need to be taken into account.
Mohd. Iqbal et al., International Journal of Integrated Engineering Vol. 12 No. 5 (2020) p. 124-129
126
The real picture of the workstation is shown in Fig. 1. The first figure (a) shows the real camera picture of a worker
in his workstation. The second figure (b) shows two dimension approach which considered as workstation design
parameters namely scope distance (A), scope height (B) and chair height (C). And, the third figure (c) shows the
simulation model which developed by Delmia V5 software showing a worker and the workstation components.
(a) (b) (c)
Fig. 1 - The workstation view in different visual approach: (a) Real camera picture; (b) 2D view; (c) Simulation
model
Furthermore, Fig. 2 shows ergonomics performances of the workstation which consist of (a) production cycle time
(Ttask), (b) working posture (Ptask) and (c) recommended weight limit (Wtask). The performances are measured using
Delmia V5 software for Method Time Measurement (MTM), Raid Upper Limb Assessment (RULA) method and NIOSH
recommended weight limit method respectively [9-11].
(a) (b) (c)
Fig. 2 - The workstation performances by Delmia V5 software: (a) Cycle time; (b) Working posture; (c) Weight
limitation
Design of Experiment (DEO) was conducted using Design Expert Statistical Software with Central Composite
Design of Response Surface Methodology [7], [12], [13], [14]. Based on the space constrain, the lower, middle and upper
limit of the design parameters were set as shown in Table 1. Fifteen simulation experiments with different dimensions of
design parameters were constructed by the DEO method as shown in Table 2.
Table 1 - The dimension of workstation design parameters
Parameters Factor Level Delta
-1 0 1
A (mm) 340 370 400 30
B (mm) 265 285 305 20
C (mm) 420 450 480 30
Mohd. Iqbal et al., International Journal of Integrated Engineering Vol. 12 No. 5 (2020) p. 124-129
127
Table 2 - The result of the experiments
Run Factor 1
A: Scope
Distance (mm)
Factor 2
B: Scope Height
(mm)
Factor 3
C: Chair Height
(mm)
Response 1
Ttask
(s)
Response 2
Ptask
Response 3
Wtask
(kg)
1 400.0 305.0 420.0 19.362 5.124 16.086
2 400.0 265.0 480.0 20.796 5.149 16.244
3 370.0 285.0 450.0 19.522 4.868 16.067
4 370.0 256.8 450.0 19.614 5.126 16.172
5 370.0 285.0 450.0 19.522 4.868 16.067
6 370.0 285.0 450.0 19.522 4.868 16.067
7 340.0 265.0 420.0 19.66 5.267 16.028
8 370.0 285.0 450.0 19.522 4.868 16.067
9 370.0 313.2 450.0 19.75 5.186 16.112
10 327.7 285.0 450.0 20.31 5.17 16.107
11 370.0 285.0 492.3 20.387 5.325 16.143
12 370.0 285.0 450.0 19.522 4.868 16.067
13 370.0 285.0 407.7 20.108 5.331 16.132
14 340.0 305.0 480.0 21.267 5.203 16.033
15 412.3 285.0 450.0 20.048 4.729 16.281
4. Discussion
Fifteen simulation experiments were conducted as suggested by the DOE. The performances were recorded based
on the result that given by Delmia V5 software, as shown in Fig. 2. The results of the experiments were shown in Table
2. The results were then statistically analyzed by using Design Expert Software. Analysis of Varian (ANOVA) showed that the model of the cycle time (Ttask) was significant with Fvalue = 2294.96
and P-value probability > F is less than 0.0001. Values of "Prob > F" less than 0.05 indicate model terms are significant.
In this case A, B, C, AB, BC, A2, B2, C2 are the significant model terms which influence the value of Ttask. All of the
design parameters gave significant effect to the cycle time as shown by the graphs in Fig. 3. It was clear from the ANOVA
and Fig. 3 that all of the effects were not linier and interactions were occurred among all of the design parameters. Fig. 4
showed the effect of design parameters to the working posture (Ptask). Scope height and chair height gave significant
effect to the working posture as shown by the graphs in Fig. 3 (a). Increasing the chair height from 420 to 450 cm will
slightly decrease the PTask, but when the chair height increased from 450 to 480 cm the PTask increased exponentially.
The interaction occurred between scope height and chair height, as shown in Fig. 4 (b). When the scope height increased
at the lower level of the chair height, the Ptask increased. However, when the scope height increased at the higher level
of the chair height, the Ptask did not change significantly. Fig. 5 shows the effect of design parameters to the weight
limitation (Wtask). Scope distance and scope height gave significant effect to the working posture as shown by the graphs
in Fig. 3 (a). Increasing the scope distance will decrease the WTask, and increasing the scope height will decrease the
Wtask. No interaction among the design parameters were found.
(a) (b)
Fig. 3 - The graph for cycle time Vs design parameters: (a) Scope distance and scope height; (b) Scope distance
Mohd. Iqbal et al., International Journal of Integrated Engineering Vol. 12 No. 5 (2020) p. 124-129
128
(a) (b)
Fig. 4 - The graph for working posture Vs design parameters: (a) Scope height and chair height; (b) Scope height
(a) (b)
Fig. 5 - The graph for weight limitation Vs design parameters: (a) Scope distance and scope height; (b) Scope
distance
The best configuration was selected by choosing the lowest cycle time, the lowest working posture value and the
highest weight limitation. However, it was nearly impossible to gather all of the best conditions. Therefore, a subjective
judgement was taken to select the closest ideal condition. As the result, experiment 15 has been considered as the best
configuration (scope distance = 412.3 cm, scope height = 285 cm and chair height = 450 cm) that gave the best
performance of the workstation (cycle time = 20.048 seconds, working posture = 4.729 and weight limitation = 16.281
kg).
5. Conclusion
The study on the effect of the design parameters (scope distance, scope height and chair height) to the ergonomic
performances (cycle time, working posture and weight limitation) has been presented. This study reveals that the best
configuration is selected by choosing the lowest cycle time, the lowest working posture value and the highest weight
limitation. While, the best workstation design according to an optimum ergonomic performance is selected through a
subjective judgment approach by looking the closest ideal condition amongst the experiment values obtained. In addition,
all of the design parameters contributed significantly to the ergonomic performances. However, the level of contributions
and interactions varied among the parameters. Further optimization study would be required in order to find optimum
solution to measure ergonomics performances towards a workstation design.
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Assoc. Prof. Ir. Ts Dr Riduan Yunus, Universiti Tun Hussein Onn Malaysia
Assoc. Prof. Dr Nabilah Ibrahim, Universiti Tun Hussein Onn Malaysia
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Dr Mohd Azhar Harimon, Universiti Tun Hussein Onn Malaysia
Dr Muhammad Faisal Mahmod, Universiti Tun Hussein Onn Malaysia
Dr Nor Akmal Mohd Jamail, Universiti Tun Hussein Onn Malaysia
Prof. Dr Mohammad Faiz Liew bin Abdullah, Universiti Tun Hussein Onn Malaysia
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Prof. Dr Yuntian Feng, Professor (Computational Engineering), Swansea University, United Kingdom
Prof. Dr Ismail Abustan, Professor (Civil Engineering), Universiti Sains Malaysia, Malaysia
Prof. Dr Ismail Bakar, Professor (Civil Engineering), Research Centre for Soft Soils, Malaysia
Prof. Dr Yoshimi Sonoda, Professor (Civil Engineering), Kyushu University, Japan
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Dr Mohd Khaidir Abu Talib, Universiti Tun Hussein Onn Malaysia
Dr Siti Hidayah Abu Talib, Universiti Tun Hussein Onn Malaysia
Dr Noorwirdawati Ali, Universiti Tun Hussein Onn Malaysia
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©International Journal of Integrated Engineering(IJIE)
ISSN : 2229-838X e-ISSN : 2600-7916
19/07/20 09.34Editorial Team | International Journal of Integrated Engineering
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19/07/20 09.29Vol 12 No 5 (2020): Special Issue 2020 : Mechanical Engineering & Covid-19 | International Journal of Integrated Engineering
Page 1 of 4https://publisher.uthm.edu.my/ojs/index.php/ijie/issue/view/245
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HOME ARCHIVES Vol 12 No 5 (2020): Special Issue 2020 : Mechanical Engineering & Covid-19
PUBLISHED: 09-07-2020
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Analysis of the Supply Chain Disruption Risks in the Malaysian Automotive Remanufacturing Industry- a Case Study
Bump Energy for Durability Prediction of Coil Spring Based on Local Regularity Analysis
Analysis of Automotive Component Design for Reparation using Additive Manufacturing Technology
Assessing the Safety Behaviour of the Bus Express Driving Condition from the Passengersʼ Perspective
Improvement of a Lightweight Aluminium Cylinder Block Design Using Finite Element Stress Analysis
Integrating Green Affective Values and Materials Selection in Automotive Design: A Preliminary Study
Relationship between Driverʼs Dynamic Pressure Distribution with their Anthropometric Variables on Car Seat underPaved Road
Atomistic investigation on the effect of temperature on mechanical properties of diffusion-welded Aluminium-Nickel
ARTICLES
Hawa Hishamuddin, Nuramilawahida Mat Ropi, Dzuraidah Abd Wahab 1-11
Chuin Hao Chin, Shahrum Abdullah, Salvinder Singh Karam Singh, Ahmad Kamal Ariffin, Dieter Schramm 12-19
Siti Syahara Mad Yusoh, Dzuraidah Abd Wahab, Abdul Hadi Azman 20-26
Shahrum Abdullah, Salvinder Singh Karam Singh, Abdul Hadi Azman, Muhamad Razuhanafi Mat Yazid, HawaHishamuddin, Wan Aizon Wan Ghopa, Aini Hazwani Shahrir, Ahmad Kamal Ariffin Mohd Ihsan, Dzuraidah Abd. Wahab
27-33
Mohamad A Arsah, Syed M A Syed Mohd Yusoff Sobbry, Tengku N A Tuan Kamaruddin, Azmi Osman 34-42
See Junn Wayne, Novita Sakundarini, Christina May May Chin, Raja Ghazilla Raja Ariffin , Sharifah Nadya Syed Azmi 43-54
Mohd Faizal Mat Tahir, Nor Kamaliana Khamis, Prof Dr, Nabilah Sabri, Zulaikha Hasani 55-61
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etho
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19/07/20 09.29Vol 12 No 5 (2020): Special Issue 2020 : Mechanical Engineering & Covid-19 | International Journal of Integrated Engineering
Page 2 of 4https://publisher.uthm.edu.my/ojs/index.php/ijie/issue/view/245
Effect of Including Periodic Boundary Condition on the Fatigue Behaviour of Cancellous Bone
Fatigue Crack Growth Behaviour of Sandwiched Metal Panel of Aluminium and Mild Steel under Constant AmplitudeLoading
Energy Absorption at High Strain Rate of Magnesium Alloy AZ31B
Point Absorber Method as Wave Energy Convertor Device for Power Generation: Effect of Buoy Arrangements
Fracture Behavior of RT-PMMA Under Impact Loading
Sound Velocity Profile (SYP) at Strait of Malacca for Maritime Warfare Usage
The Study on Ergonomic Performances Based on Workstation Design Parameters using Virtual Manufacturing Tool
Performances of Jatropha and Waste Cooking Oil Biodiesel Blends Fuel Combustion using Diesel Engine
Prediction of Flow Pattern Behaviour Behind Square Cylinder using Computational Fluid Dynamic (CFD) Approach
A Review of Surface Texturing in Internal Combustion Engine Piston Assembly
Construction of Driving Seat Frame and 2-Dof Motion Simulator
Mohamad Zaenudin, M. N. Mohammed, S. Al-Zubaidi 62-69
Fatihhi Szali Januddi 70-80
A. H. Isahak, M. F. Abdullah, M. K. Faidzi, A. Ali, M. M. Mubasyir 81-90
M. M. Mubasyir, M. F. Abdullah, K. Z. Ku Ahmad, R. N. R. Othman, A. H. Isahak 91-96
M. A. Yussof, N. I. Ismail, M. J. Aiman, M. F. Abdullah, B. A. Gurunathan, M. R. A. Rahman, M. R. Saad 97-103
Norazrina Mat Jali, Patrice Longere 104-107
Mohd Najib Abdul Ghani Yolhamid, Ainul Husna Abdul Rahman, Mohd Azzeri Mohd Naiem, Mohd Norsyarizad Razali,Mohd Arif Ahmad
108-123
Mohd Iqbal, Iskandar Hasanuddin, Azmi Hassan, Mohd Syafiq Mohd Soufi, Friesca Erwan 124-129
A. R. Norwazan, N. Norzaima, M. R. A. Rahman, M. S. R. Nasir 130-136
N. Nordin, E. Benard, A.H.A Kamal, M.T Ahmad 137-145
Muhammad Asyraf Mohd Azmi, Wan Mohd Faizal Wan Mahmood, Jaharah A. Ghani, Mohammad Rasidi MohammadRasani
146-163
Intan Mastura Saadon 164-170
19/07/20 09.29Vol 12 No 5 (2020): Special Issue 2020 : Mechanical Engineering & Covid-19 | International Journal of Integrated Engineering
Page 3 of 4https://publisher.uthm.edu.my/ojs/index.php/ijie/issue/view/245
Exploring the Impact of Supplier Development Practices on Manufacturing Responsiveness in Malaysia
Initial Study of Factors on Green Supply Chain Management, Green Supplier Strategy and Work System Performance
Mechanical Properties of Epoxy Composites Containing Carbon Black and Graphene
Development of a Noise Filtering Algorithm for Strain Signals Using the Fast Fourier Transform
Influence of Pretreatments on Sustainability of Bioethanol Production from Napier Grass
Design for Manufacturability (DFM) of 3D Printed Parts Fabricated Using Open Source 3D Printer
Preparation and Performance Test of PEFB Reinforced Box Waste Coated Superhydrophobic Coating for Shoe SoleApplication
Mobile Augmented Reality Hand Wash (MARHw): Mobile Application to Guide Community to AmeliorateHandwashing Effectiveness to Oppose Covid-19 Disease
A Partitioning-based Approach for Clustering COVID-19 Drugs and Co-Medication for Safe Use
Analysis on Preparation, Application, and Recycling of Activated Carbon to Aid in COVID-19 Protection
Solid Oxide Fuel Cell (SOFC); A New Approach of Energy Generation during the Pandemic COVID-19
An Innovative Approach for Environmental Monitoring by Solar Powered Kite
Rahayu Tukiman 171-177
Norhafiza Mohamed 178-184
R. N. Othman, I. A. Rahman, M. K. Faidzi, K. Z. Ku Ahmad 185-190
Desy Asrina, Teuku Edisah Putra, Husaini Husaini 191-196
Sutida Marthosa, Wirote Youravong, Ekasit Anancharoenwong 197-202
Nurul Ain Maidin 203-209
Noraini Marsi 210-216
Hafizul Fahri Hanafi 217-223
Dr, Aida Mustapha, Dr 224-232
Md Sumon Reza, ABM Kamrul Hasan, Shammya Afroze, Muhammad S. Abu Bakar, Juntakan Taweekun, Abul K. Azad 233-244
Shammya Afroze, Md Sumon Reza, Quentin Cheok, Juntakan Taweeku, Abul K. Azad 245-256
Riazul Islam Thakur, Muhammad Irfan Ishak, chila kaewpraek, Yap Boon Kar, Kazi Sajedur Rahman, Kuaanan Techato, Md.Akhtaruzzaman, Sieh Kiong Tiong, Nowshad Amin
257-265
19/07/20 09.29Vol 12 No 5 (2020): Special Issue 2020 : Mechanical Engineering & Covid-19 | International Journal of Integrated Engineering
Page 4 of 4https://publisher.uthm.edu.my/ojs/index.php/ijie/issue/view/245
©International Journal of Integrated Engineering(IJIE)
ISSN : 2229-838X e-ISSN : 2600-7916
This OJS site and its metadata are licensed under a Creative Commons Attribution-NonCommercial-ShareAlike 4.0 International License