Development of an integrated ergonomics principles framework with manufacturing process flow in Malaysian industry

• Main Author: Mohd Azli Lee, Fatin Ayuni
• Format: Thesis
• Language: English; English
• Published: 2022
• Subjects: T Technology (General); TA Engineering (General). Civil engineering (General)
• Online Access: http://eprints.utem.edu.my/id/eprint/26892/1/Development%20of%20an%20integrated%20ergonomics%20principles%20framework%20with%20manufacturing%20process%20flow%20in%20Malaysian%20industry.pdf; http://eprints.utem.edu.my/id/eprint/26892/2/Development%20of%20an%20integrated%20ergonomics%20principles%20framework%20with%20manufacturing%20process%20flow%20in%20Malaysian%20industry.pdf; http://eprints.utem.edu.my/id/eprint/26892/; https://plh.utem.edu.my/cgi-bin/koha/opac-detail.pl?biblionumber=122072

Manufacturing engineers generally schedule their activities along manufacturing process flow. Nevertheless, there are limited documentations that integrate ergonomics principles into the manufacturing process flow format. This study aims to address the issue by developing an ergonomics framework that integrates ergonomics principles with manufacturing process flow. This research was divided into three phases. In Phase 1, ergonomics implementation challenges among practitioners in Malaysian manufacturing industry was identified through thematic analysis of literature reviews and interviews. In Phase 2, a proposed framework mapping general ergonomic improvements to the general manufacturing process flow were generated through in-depth discussion and generative sessions. Phase 3 is a validation process, where the study outcomes were reviewed and validated by professional practitioners through a mixed method of descriptive analysis and Fuzzy Delphi Method (FDM). Phase 1 findings showed that limitations of ‘ergonomics documentation’ and ‘ergonomics knowledge’ are identified as primary challenges faced by engineers in implementing ergonomics. Results from Phase 2 revealed six general manufacturing process flows themes that are applicable in different Malaysia’s manufacturing sectors: ‘Incoming raw materials’, ‘inspection of raw materials', ‘assembly/production/fabrication’, ‘quality inspection’, ‘packaging’, and ‘shipment of endproduct’. These six process flows were mapped to sixteen ergonomic engineering improvement components, which related to provision of tools, equipment, devices, or mechanisms to 1) ‘improve working height level’; 2) ‘reduce forceful exertion’; 3) ‘reduce contact stress’; 4) ‘assist manual work and manual material handling activities’; 5)’ reduce excessive reach’; 6) ‘improve grips’; 7) ‘maintain neutral postures of neck’; 8) ‘minimize the frequency of work movements’; 9) ‘maintain neutral postures of upper limbs’; 10) ‘minimize fatigue’; 11) ‘reduce vibration’; 12) ‘improve space and clearance’; 13) ‘improve visibility’; 14) ‘improve layout and arrangement’; 15) ‘allow good body balance and stability’; and 16) ‘improve the environment’. Validation in Phase 3 with all expert participants shows general agreement rating obtained on the ergonomics implementation challenges, and the newly proposed framework’s components. The FDM findings show that assembly/production/fabrication process acquires all the general ergonomic engineering improvements. Eight general ergonomic engineering improvements have been determined to be applicable in all processes within the manufacturing process flows. In conclusion, the developed framework may provide an overview or roadmap of how and where manufacturing engineers and managers can actively support the implementation of ergonomics initiatives in a manufacturing process flow format.