Subject: Human Factors and Workplace Management

1. www.postersession.com
To improve ergonomic design (macro and micro) at assembly and
pack- out production line at Toy Industry:-
1. Macro Ergonomics is an approach for organization design,
working system and also human–machine, environment–human
and user–system interaction.
2. Micro Ergonomics to improve the performance of the whole work
system as well as to reduce the stress imposed on the working
human being by means of analyzing the task, the working
environment and the man–machine interaction
DESIGN MACRO & MICRO ASSEMBLY AND PACK-OUT AT TOY INDUSTRY
Prof Madya Dr Siti Zawiah Binti Md Dawal, Thamil Selvam A/L Kanniah, Ooi Hoong Chuan, Marina Binti Muhamad,
Tun Mohamad Ariffin Bin Yahaya, Yim Yan Han, Ahmad Shahrazi Bin Md.Sidik
Faculty of Engineering, University of Malaya, Kuala Lumpur
OBJECTIVES
ERGONOMICS
Macro Ergonomics
Rules for the design
Organization, Production
& Workgroup
Micro Ergonomics
Rules for fit the
task towards people
SCOPE OF WORK
Ergonomic issues at Assembly and Pack-up scope of work –
(Musculoskeletal Diseases (MSD) issues):
1. Reaching problem to pick up parts
2. Space constraint
3. Cycle time
PROCESS FLOW CHART
CURRENT WORK PLACE DESIGN
Existing Work Place design Concern as Below:
1. Multi-tasking – 10 sec per process cycle
2. Siting position – At the edge of the conveyor and far from parts
(not within ergonomic reach)
3. Awkward/extreme body movement – Need to twist his/her
body to pick up parts for assembly
4. Space constraint – Can lead to trip and fall
ASSEMBLY & PACK-OUT PROCESS
Zinc Alloy (Die Casting)
Install Inside Furnace
Air Pocket (Segregate
Chassis)
Chassis Painting
Hot Stamp Sticker
Assembly Pack Out (Chassis, Barbell, Interior component,
Packaging, Shipping)
Hot Wheels’ Process Flow Chart
Incoming Material – Zinc alloy, plastic resin, paint, ink,
lacquer, solvent chemical and others
Die Casting
Plastic Injection
Molding
Regrind Plastic
Material
Zinc
Alloy Plastic
Resin
De-gating
Tumbling
Casted
Parts
Sorting
Chassis
Component
Ransburg
Chassis
Component
Paint &
Solvent
Tampo Printing
Hands Spray
Paint &
Solvent
Ink &
Solvent
Vacuum Metalizing
Lacquer &Solvent
Aluminium Stables
Graphic Fusion
Plating
Chemical &
Zinc Plating
Plastic Injection
Molding
Wheel Hot
Stamping
Moulded
Wheels
Barbell
Assembly
FOLL
AXLE WIRE
Plastic Injection
Molding
Supplier
Plastics
Interiors
Windows
Part
Finishing GoodVacuum Forming
Assembly
Pack Out
Blister & PV rolls
Body
Components
Decal
Plastic
Resin
MICRO ERGONOMIC HUMAN ERROR
1. Body twisting during pick and place process
2. Reaching parts that located far from the conveyor causing
muscle strains (arms, back)
3. Frequent awkward body movement
MICRO ERGONOMIC PROBLEMS
1. Assembling wrong parts due to different models (limited
edition)
2. Operator assuming that moving parts will correct since same
task performing
3. Pressing wrong control button and damage the product
4. Bypass the task (short cuts)
5. Lost of concentration while performing tasks due to long
working hours and high concentration needed.
MICRO ERGONOMIC IMPACT – SAFETY & HEALTH
1. Injury – Pressing button when the process is not yet ready
2. Fatigue – Due to work load & long sitting / standing hours
3. Trip & Fall – Picking up parts which located at the far end
4. Vision Problems – Due to the tiny product assembly of toy
parts
5. Stress – Due to the need of focusing and continuous task &
repetitiveness
MACRO ERGONOMIC PROBLEMS
1. No job rotation during prolong working hours
a) Hand strain and long hour standing causing back pains
b) Absenteeism – Due to back pain
c) High turn over – Due to medical issue (resulting on back to
home country/change job)
d) Competitiveness – Leads to reduction in team work due to
task completion incentives to those who finishes earlier.
e) Multi-tasking in short process cycle type (10sec)
2. Safety Incident
a) Lack of concentration due to continuously in task may
caused the operator accidently pressing the button even the
product is not assembled or placed (These will lead to
accident – hand pinch)
3. Economically/Cost
a) Medical payment by the company increased tremendously
due to medical issue by operator
b) Medical claim – reimbursement from the operator whereby
the operator went to non panel clinic and specialist centre.
RECOMMENDATIONS (MANAGEMENT)
 Counselling
 Coaching, tea-talk to identify problems with work
 One-to-one session for personal issues consultation
 Program on Safety Campaign
 Incident early reporting system
 Medical symptoms awareness programs
MACRO PLANNING RECOMMENDATIONS
1. Job plan – Look at overall planning on the production request
2. Job description – Nature of Work
3. Job matching – Plan & dedicate job function to the right operator
4. Job rotation – Assigned dedicated job for certain hours and
exchange with other operators (suggestion 4 for each task/cycle)
5. Job satisfaction – Reduce long hours with exercise session in
the middle of cycle.
6. Work shifts – 8 to 12 hours shift works. shift can be shorten to
8hrs to eliminate absenteeism
7. Absenteeism – Motivation/counselling to reduce absenteeism
due to stress
8. Safety incident – Educate operators on the importance of safety
at workplace and how to report of the occurrence
MICRO JOB PLANNING (DESIGN IMPROVEMENT)
1. The nature of job is operator assemble the toys spare part in an
assemble & pack – Out process
2. This process are access by operator to get the parts from non
ergonomic standard
Solution
• Design with automation – so that parts pocket cart easily
reached for assembles
 Employee assistance Program
 Financial problem
consultation, training
 Good Catch Program
 Workers that found the
hazard will be rewarded
 Recreation
 Safety Improvement,
Safety Hero
New Design : Which is easily able to pick and place at the car on the conveyor
Cost Incurred for The Automation Project → USD 120K || ROI = 2 years
CONCLUSION
• Micro & Macro ergonomic issues can be improved without
compromising the quality of production and employees’ safety &
health.
• Ergonomic issues against employees (operator) are preventable
without any negligence and circumstance
REFERENCES
1. Tahriri, F., Dawal, S.Z.M., Tahan, Z. (2014) Multiobjective Fuzzy Mixed Assembly
Line Sequencing Optimization Model. In: J Appl Math, vol. 2014, pp. 1-19.
2. Dawal, S.Z.M., Ismail, Z., Taha, Z. (2011) Human Factors and Ergonomics Model
and Application in Automotive Industries: Focus on Job Satisfaction. In: New Trends
and Developments in Automotive Industry, Prof. Marcello Chiaberge (Ed.), InTech.
3. Dawal, S.Z.M., Taha, Z. (2009) Job satisfaction model for manufacturing industry:
focus on ergonomics and human factors in work design. In: IEEE Toronto
International Conference on Science and Technology for Humanity, SEP 26-27,
2009, Toronto.