Design Development of a Pallet Stacker through Integration of Ergonomic Assessment and Quality Function Deployment (QFD) at Machine Shop in UTeM

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1 UNIVERSITI TEKNIKAL MALAYSIA MELAKA Design Development of a Pallet Stacker through Integration of Ergonomic Assessment and Quality Function Deployment (QFD) at Machine Shop in UTeM Report submitted in accordance with the requirements of the Universiti Teknikal Malaysia Melaka for the Bachelor s in Manufacturing Engineering (Manufacturing Management) with Honors. By Mohd Fahmi Bin Baharuddin Faculty of Manufacturing Engineering April 2008

2 UTeM Library (Pind.1/2005) oval UNIVERSITI TEKNIKAL MALAYSIA MELAKA (UTeM) BORANG PENGESAHAN STATUS TESIS* JUDUL: DESIGN DEVELOPMENT OF A PALLET STACKER THROUGH INTERGRATION OF ERGONOMIC ASSESSMENT AND QUALITY FUNCTION DEPLOYMENT (QFD) AT MACHINE SHOP IN UTeM SESI PENGAJIAN: 2007/2008 Saya MOHD FAHMI BIN BAHARUDDIN mengaku membenarkan tesis (PSM/Sarjana/Doktor Falsafah) ini disimpan di Perpustakaan Universiti Teknikal Malaysia Melaka (UTeM) dengan syarat-syarat kegunaan seperti berikut: 1. Tesis adalah hak milik Universiti Teknikal Malaysia Melaka. 2. Perpustakaan Universiti Teknikal Malaysia Melaka dibenarkan membuat salinan untuk tujuan pengajian sahaja. 3. Perpustakaan dibenarkan membuat salinan tesis ini sebagai bahan pertukaran antara institusi pengajian tinggi. 4. **Sila tandakan ( ) SULIT TERHAD TIDAK TERHAD (TANDATANGAN PENULIS) (Mengandungi maklumat yang berdarjah keselamatan atau kepentingan Malaysia yang termaktub di dalam AKTA RAHSIA RASMI 1972) (Mengandungi maklumat TERHAD yang telah ditentukan oleh organisasi/badan di mana penyelidikan dijalankan) Disahkan oleh: Alamat Tetap: NO 160, Jln Sri Intan, Taman Sri Intan II, Hutan Melintang, Perak. Tarikh: 24 March 2008 (TANDATANGAN PENYELIA) Cop Rasmi: Tarikh: * Tesis dimaksudkan sebagai tesis bagi Ijazah Doktor Falsafah dan Sarjana secara penyelidikan, atau disertasi bagi pengajian secara kerja kursus dan penyelidikan, atau Laporan Projek Sarjana Muda (PSM). ** Jika tesis ini SULIT atau TERHAD, sila lampirkan surat daripada pihak berkuasa/organisasi berkenaan dengan menyatakan sekali sebab dan tempoh tesis ini perlu dikelaskan sebagai SULIT atau TERHAD.

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4 DECLARATION I hereby, declared this report entitled Design Development of Pallet Stacker through Integration of Ergonomic Assessment and Quality Function Deployment at Machine Shop in UTeM is the result of my own research except as cited in references. Signature :.. Author s Name : Date : i

5 APPROVAL This report submitted to the senate of Universiti Teknikal Malaysia Melaka (UTeM) and has been as partial fulfillment of the requirements for the Bachelor of Manufacturing Engineering (Manufacturing Management) with Honors. The members of the supervisory committee are as follow: MR. ISA BIN HALIM Main Supervisor Faculty of Manufacturing Engineering Universiti Teknikal Malaysia Melaka ii

6 ABSTRACT Material handling device (MHD) is an equipment used to help workers in manufacturing activities especially in transferring goods and materials. The advantage of MHD is it can reduce the load of lifting task thus minimize the potential risk of musculoskeletal problems. This study presents the design and development of MHD through integration of ergonomics assessment and Quality Function Deployment (QFD). The specific objectives of this study are to determine the safe lifting limit, redesign the MHD i.e. pallet stacker and evaluate the effectiveness of the proposed design. To achieve mentioned objectives, Rapid Upper Limb Assessment (RULA) was used to evaluate the working posture; Quality Function Deployment (QFD) was utilized to redesign the pallet stacker; Push and pulling analysis was adopted to determine the lifting limit of worker. Based on result obtained, the RULA score and push pulling analysis shows the injuries happened which neck, arm, and lower back while are working. Meanwhile, based on the QFD results some part of pallet stacker which handle, platform, wheel should be improve in order to reduce risk of injuries. From conducted study, the author concluded that the approaches are able to adopted redesign a pallet stacker that saves to the worker. iii

7 ABSTRAK Alat bantuan bagi pengantara adalah alat yang digunakan bagi membantu pekerja di dalam industri pembuatan terutamanya memindahkan barangan dan alatan. Kelebihannya ialah ia dapat mengurangkan berat untuk mengangkat barangan dan juga mengurangkan potensi bagi pekerja untuk mendapat kecederaan. Tujuan kajian ini adalah membincangkan mengenai reka bentuk dan pembangunan bagi alat bantuan pengatara melalui ergonomik intergrasi dan Quality Function Deployment (QFD) didalam industri. Objektif kajian ini adalah untuk menentukan tahap mengangkat yang selamat, mereka bentuk semula pallet stacker dan menilai keberkesanan reke bentuk yang baru. Untuk mencapai objektif kajian ini, perisian RULA, QFD dan analisis Push and Pulling telah digunakan. Daripada keputusan kajian yang di lakukan dengan menggunakan perisian RULA dan Push and Pulling, sebahagian anggota badan seperti leher, pinggang, lengan di dapati ketika bekerja. Manakala, dari keputusan QFD yang dijalankan, sebahagian bahagian pallet stacker perlu diubah suai antaranya platform, pemegang tangan dan roda. Daripada analisis yang dijalankan, keputusan kajian menunjukkan bahawa pelaksanaan kajian ini dapat mengurangkan potensi untuk mendapat kecederaan ketika menggunakan alat pengantara tersebut. iv

8 DEDICATION For my beloved parents: Baharuddin Bin Ibrahim Latifah Binti Mohammed Dawood And for my adored brothers and sister: Norwahidah Binti Baharuddin Mohd Fadhli Bin Baharuddin Mohd Anas Bin Baharuddin Mohd Ainul Alwi Bin Baharuddin And my inspiration: Noor Juliani Ngah v

9 ACKNOWLEDGEMENT Bismillahhirrahmanirrahim First of all, I would like to express my very special thank to my beloved parents, Mr. Baharuddin Bin Ibrahim and Madam Latifah Binti Mohammed Dawood for their full support, and guidance which I receive from them helps me to be strong and patience to finish up this study. Without their prayer and blessing, I would possibly not finish this study. Then, with my great respect, I would like to thank to Mr. Isa Bin Halim who has excellently supervised me, given good and existing suggestions and criticism to the process of the work and motivate me in a good way which makes me improve in this study. Not forgotten, I would like to thank to all my friends for continuously supporting, motivating and helping me in completing this study. Lastly, to all people that involve in this study, thanks for your cooperation and kindness. Mohd Fahmi Bin Baharuddin vi

10 TABLE OF CONTENTS Declaration...i Approval..ii Abstract..iii Abstrak...iv Dedication...v Acknowledgement..vi Table of Contents..vii List of Figures.xii List of Tables...xvi List of Abbreviations, Symbols, Specialized Nomenclature xvii 1.INTRODUCTION 1.1 Background Problem Statement Objectives of study Scope and limitation of study Potential benefits of study Report Outline 7 2. LITERATURE REVIEW 2.1 Introduction Design Design criteria Design of stacker Material Handling Device (MHD) Definition of material handling device Material handling device task The proper design of Material handling device Ergonomics. 15 vii

11 2.4.1 Definition of ergonomics Ergonomics in industry Manual material handling Introduction to manual material handling Definition of manual material handling Principle of manual material handling Fundamental approach the manual material handling Biomechanical approach Physiological approach Psychophysical approach Manual handling risk factor Work related musculoskeletal disorders Work related musculoskeletal disorders Musculoskeletal disorders (MSDs) activities Load handling Lifting safety Pushing and pulling Observation method for ergonomics assessments Rapid Upper Limb Assessment (RULA) Rapid Entire Body Assessment (REBA) NIOSH lifting equation Lifting index (LI) Recommended weight limit (RWL) Direct method assessment Electromyography (EMG) Electrogoniometers Lumbar Motion Monitoring (LLM) Carry analysis CAD/CATIA Quality Function Deployment (QFD) Definition of Quality Function Deployment (QFD) House of quality 39 viii

12 Foundation of house of quality (planning matrix) Steps to build House of Quality..40 a) Step 1 - Customer requirement (Voice of Customer).40 b) Step 2 - Technical descriptors (Voice of Engineer)...41 c) Step 3 - Relationship between customer requirements and technical descriptors(trade-off) 43 d) Step 4 - Interrelationship between technical descriptors 44 e) Step 5 - Prioritized customer requirements Previous study METHODOLOGY 3.1 Introduction Methodology Determine the safe lifting limit regarding to manual material handling activities Redesign current pallet stacker in order to improve Working Posture Evaluate the effectiveness of proposed design of stacker Summarization of methodologies CASE STUDY 4.1 Background of case study Machine shop laboratory Material handling device used Pallet stacker Assessment of case study Design of pallet stacker Job activities when used the pallet stacker Assessment of working posture Case studies Transferring the metal from the storage onto Laser Cutting Machine...67 ix

13 5. RESULT AND ANALYSIS 5.1 Introduction Determine the safe lifting limit regarding to manual material handling activities Redesign current pallet stacker to improve working posture Questionnaire result QFD analysis Characteristic of customer requirement Develop the House of Quality (HOQ) Evaluate the effectiveness of proposed design of Pallet stacker Redesign of pallet stacker regarding from the QFD analysis Analysis for current design Lift the object by using the current design of pallet stacker result analysis Pushing process to move the object by using the pallet stacker analysis Pulling process to move the object by using the current design of pallet stacker analysis The analysis for transfer the raw material from the pallet stacker into laser cutting machine Analysis for propose design Lift the object by using the new design of pallet stacker result analysis Pull the object by using the new design of pallet stacker result analysis Pull the object by using the new design of pallet stacker result analysis Analysis to transfer process the raw material from the pallet stacker into laser cutting machine Comparison between the current design and new design DISCUSSION 6.1 Introduction To determine the safe lifting limit regarding to manual materials handling activities To redesign current Pallet Stacker in order to improve working posture 124 x

14 6.3.1 RULA analysis in redesign the current pallet stacker Lift the object Pull the pallet stacker Push the pallet stacker Transfer the raw material from the pallet stacker into laser cutting machine Push and Pull analysis for pushing and pulling pallet stacker The workers needed regarding to the design of pallet stacker for material handling device activities Design improves for the current of pallet stacker Evaluate the effectiveness of the design Lift the object process Pull the pallet stacker process Push the pallet stacker process Process to transfer the material using pallet stacker Comparison from the working posture result CONCLUSION 7.1 Introduction To determine the safe lifting limit regarding to manual materials handling activities Redesign current Pallet Stacker in order to improve working posture Evaluate the effectiveness of proposed design of pallet stacker RECOMMENDATION Recommendation for design Recommendation for ergonomic activities and assessment..142 REFERENCES 144 APENDICES Appendix A Appendix B xi

15 LIST OF FIGURE 1.1 Report outline The whole body and part of the stacker in order to redesign the current design of pallet stacker The percentage of the most common worker complaints reported with respect to health and safety The key factors that must be considered when designing a safe and productive pushing/pulling task, The horizontal and vertical position of the hands relative to the subject s toes at the origin of the lift How to wear the Lumbar Motion Monitor House of Quality Determination of working posture using RULA analysis and table of Result for ergonomics activities will presented by using the Catia Software Table for data of working posture by using RULA analysis Surface grinding machine Lathe machine Horizontal band saw Boring machine Wheel cart Wheel cart Hand pallet truck Pallet stacker Pallet stacker Goniometry tool Dimension of anthropometry to measure in RULA analysis Lifting task Press jack task Push the pallet stacker task Pull the pallet stacker.70 xii

16 4.16 Transfer the object task Working posture and lifting task The percentages of respondent like the current design of the pallet stacker The percentages of respondent wish to improve or redesign The percentages of believe that the pallet stacker is helping to lift a heavy load and huge object The percentages of respondent got the pain history while handling the pallet stacker The percentages of respondent have any difficulties while handling the pallet stacker The percentages of pain detected when used the pallet stacker Statistic for platform (arm) part Statistic for platform (arm) part Statistic for wheel part Statistic for hydraulic part system Body diagram for stability of pallet stacker Body diagram for beam deflection Body diagram for pushing process Body diagram for pulling process Body diagram for lift load process QFD result analysis to redesign and improve the current of pallet stacker The current pallet stacker that been design through the QFD, RULA analysis Body diagram for new force of pushing Body diagram for new force of pulling RULA analysis result for the case study by using the current design of pallet stacker.,, RULA analysis for left sided body for lift the object RULA analysis for right sided body for lift the object The working posture pushing processes with object loaded The data result for pushing process (right side) The data result for pushing process (left). 102 xiii

17 5.29 Pushing and pulling analysis Pulling process by using Catia software Data result for pulling process (right) Data result for pulling process (left) Data result for push and pulling analysis The working posture to transfer the object Data result for working posture (left) Data result for working posture (right) RULA analysis result for the case study by using the current design of pallet stacker The result of working posture after new design of pallet stacker (left) The result of working posture after new design of pallet stacker (right) The working posture of manikin for new design of pallet stacker The result of working posture after new design of pallet stacker (left) The result of working posture after new design of pallet stacker (right) The RULA analysis result for pulling process by using the new design of pallet stacker The result of working posture after new design of pallet stacker (right) The result of working posture after new design of pallet stacker (left) The working posture to transfer the object The result of working posture after new design of pallet stacker (right) The result of working posture after new design of pallet stacker (left) The layout that does not ergonomic and must be modify immediately so that it can decrease the risk of injuries to all user The new design of pallet stacker Comparison between current design and new design based on RULA score for right side Comparison between current design and new design based on RULA score for left side Comparison between current design and new design based on RULA score for right side xiv

18 6.6 Comparison between current design and new design based on RULA score for left side Comparison between current design and new design based on RULA score for left side Comparison between current design and new design based on RULA score for left side Comparison between current design and new design based on RULA score for left side Comparison between current design and new design based on RULA Score for right side 137 xv

19 LIST OF TABLES 3.1 Table for data of working posture by using RULA analysis The anthropometric data from the technicians Frequency Multiplier Coupling Multipliers Technical specifications of current design of pallet stacker The mean result and importance to customer in order to know which one the critical part of improvement Technical specifications of new design of pallet stacker The comparison of ergonomic analysis between the current design and proposed new design of pallet stacker using RULA analysis The comparison of ergonomic analysis between the current design and proposed new design of pallet stacker using RULA analysis The maximum acceptable initial maximum and acceptable sustained force for pushing process That the value of pulling can accommodate force when pulling the pallet stacker Demonstrate the value scores those found from RULA analysis for pushing process Third teen part of improvement needed base on the questionnaire The result of QFD analysis xvi

20 LIST OF ABBREVIATIONS, SYMBOLS, SPECIALIZED NOMENCLATURE MHD - Material handling device CTD - Cumulative trauma disorder NIOSH - National Institute of Safety and Health NLE - NIOSH Lifting Equation MMH - Manual material handling MSD - Musculoskeletal disorder RULA - Rapid Upper Limb Assessment Analysis REBA - Rapid Entire Body Assessment Analysis QFD - Quality Function Deployment OSHA - Occupational Safe and Health Act CATIA - Computer Aided Tree Dimensional Interactive Application LLM - Lumbar Motion Monitor EMG - Electroginiometer CAD - Computer Aided Design CAM - Computer Aided Manufacturing CAE - Computer Aided Engineering xvii

21 CHAPTER 1 INTRODUCTION This chapter provides information on background of study, problem statement and objective of study. Besides, this chapter also describes the scope and limitation of study, potential benefits from the study that may significant to student, authorities, or related organizations. The outline of conducted study also presented in this chapter. 1.1 Background of Study Manufacturing industry is a critical industry in Malaysia as it contributes economy source nowadays. The development and implementation of manufacturing was responsible for one of the great advances in human history, and the industrial revolution. To stay competitive in global market, the manufacturing sector in our country needs to improve the productivity through upgrading of its primary production technology. Manufacturing firms also must achieve a degree of innovative capability in managing production operations, processes and advance to use new equipment. Through that, many factors can helps to achieve the new phenomenon after the industrial revolution in our country. For example, the uses of machining and material handling device that can help the production system working properly and smoothly. Material handling device (MHD) is a good example to help the workers in manufacturing industries especially in ergonomics application. The advantages of MHD in industry to replace repetitive lifting task has created a new sources of potential musculoskeletal problem. Material handling device is capable to move heavy objects, 1

22 such as large waste containers and other large objects that requiring mechanical assistance. The ergonomic material handling device can be used with neutral postures of the back, shoulders, wrists and knees, thereby reducing potential injury to the user. For example, the pallet stacker is a common a material handling device used in manufacturing industries. The purpose of pallet stacker used to transfer or move the objects to others location. It is can help the workers to transfer or move heavy and large objects with easily. Besides, the weight load and larger objects can decrees the consumption of the pallet lifting ability and the workers get the injuries with easily. In this case, the suitable design of material handling device can helps workers that will effectively reduced the musculoskeletal disorders work through the ergonomics applications. Ergonomics programs seek to identify and correct factors that negatively impact the physical health of their workers. Ergonomics programs seek to maximize the involvement of the workers in this process based on the simple fact that a worker is an expert on his or her job. Ergonomics also relies on actively involving workers in implementing ergonomic knowledge, procedures and changes with the intention of improving working conditions, safety, productivity, and quality. In this project, the purposes are to create a new design about the material handling device applications especially in industrial field and also as a reference to solve the ergonomic problems. Consequently, it can be useful to improve their works and reduce injuries and musculoskeletal disorders injuries problems towards them. This chapter provides an overview of the research project titled Design Development of Pallet Stacker through Integration of Ergonomic Assessment and Quality Function Deployment (QFD) in Machine Shop in UTeM. 2

23 1.2 Problem Statement In industry scenario, heavy lifting has been identified as a major factor for the development of back injuries (Marras et al., 1993; Hildebrant, 1987). Hence, primary prevention of musculoskeletal complaints requires reduction in physical load, for example by implementation of ergonomic improvements (Schneider, 2001). From this problem, the MHD is used to prevent the occupational injuries such as low back injuries and low back pain. According to the (Myung, CJ et al., 2004), mass production service in industry have replace a burden of manual material handling on workers. To reduce the problem, management has provided manual vehicles, such as carts, truck, wheelbarrows and so on. However, the others problems related to fortify the manual handling device are: a) Moving large pieces of furniture is a physically demanding task. Little has been done to decrease the strain on the body during these manual lifting tasks. (Jessica K. Paskiewicz et al., 2007) b) The three major injuries resulting from pushing and pulling trolleys and carts in food and drink industries were strains, sprains, and bruises (Health and Safety Executive, 2002). c) In other reason, lifting is a very complex task that requires the activation and coordination of the entire body (Chen, 2000; van Dieen et al., 1996). 3

24 1.3 Objectives of Study In order to solve above mentioned problems, this project tries to achieve following objectives: a) To determine the safe lifting limit regarding to manual materials handling activities. An observation was conducted to determine the safe lifting limits among the workers who involved in manual materials handling activities. b) To redesign current pallet stacker in order to improve working posture. Redesign the current pallet stacker is device to improve the working posture. The purpose is to ensure a worker is safe while handling the material using redesigned pallet stacker. c) To evaluate the effectiveness of the proposed design of pallet stacker. The effectiveness of the proposed designed of pallet stacker will be done by comparing findings of current design and improved design. 4