Car assembly is a combination of all components that form one completed vehicle unit. The work process is manually done and repeatedly, which contributes to a risk of musculoskeletal disorders (MSD). Chassis assembly is a job with a high level of complexity and associated with MSD risk for its employees. This study consists of 30 assembly activities divided into six groups based on posture and working methods used during the work process. Group A consists of 7 assemblies, Group B consists of 8 assemblies, Group C consists of 5 assemblies, Group D consists of 2 assemblies, Group E consists of 5 assemblies, and Group F consists of 3 assemblies. This study aims to compare the measurement and calculation of the risk level of MSD workers by using the RULA, REBA, and OWAS methods. The results of the measurements and computations acquired using these three approaches yielded the same risk category: 83.33 % medium risk/dangerous in working groups A, C, D, E, and F, and 16.67 % very high risk/highly hazardous in working group B. These six groups, particularly group B, requires immediate attention to reduce worker complaints of MSD.
Nowadays, in a new era of industrial revolution 4.0, there are still many manufacturing companies that tend to neglect the knowledge of optimizing the factory layout. By doing so, the productivity can be increase and lessen the burden of the operator while making sure the quality and also the number of products are also at optimum. The objective of this study is to conduct an analysis on the actual arrangement assembly line using witness software based on QRM in V model assembly and also to propose a new arrangement of the assembly line using Witness software. The data has been collected and recorded through some observation during the visit to X Company. The current layout of the V model assembly line is simulated in the Witness software to get its actual process, percentage of idle, and also the setup time. The software is also used for the new improvement of the assembly line layout to get the comparison for the current layout and after the improvement. Based on the current result, there is some station that has a high percentage of blockage occur in the layout and after the improvement, the percentage of blockage has been reduced which help in increase the production of the model per day. The data that has been recorded from the current is compared with the data after the improvement has been made to the assembly line.
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