Repetitive tasks carried out by packaging workers of fertilizer producer company. These task led to some complains of pain and fatigue on upper body part of the workers based on Nordic Body Maps (NBM) questionnaire. This is because the workers work continuously for eight hours per shift and no recovery period. This study aims to determine risk level of musculoskeletal disorders and break time calculation. In this study, using Occupational Repetitive Actions (OCRA) index to reduce the risk level. The samples according to expert judgement criteria are three workers (packer clamper, packer tailor and loader). The improvement in this study is designing work methods with break time calculation. This improvement shows the risk reduction on the left hand of the packer clamper from 4,2 to 3,4 and the right hand from 9,9 to 8,2. Risk reduction on the left hand of the packer tailor from 3,44 to 2,2 and the right hand from 5,7 to 2,26 while the risk level on the left hand of loader from 1,4 to 0,87 and in the right hand from 2,17 to 1,18.
Workers in the packaging process of pesticide factories constantly do repetitive jobs on belt conveyors, eight hours per shift. Results of preliminary observations used Nordic Body Map (NBM) questionnaire shown that there was the severity of Musculoskeletal Disorders (MSDs) on the upper body of the workers. The purpose of this research was to analyzing and evaluating the risk of exposure of those repetitive tasks, determining rest time and also determining suitable work posture. Occupational Repetitive Actions (OCRA) index used to determine the risk level of musculoskeletal disorders and rest time. The occupational repetitive actions (OCRA) index is the most precise method for analyzing and evaluating the risk of exposure to repetitive tasks. There were six activities observed in the packaging process. The highest OCRA index result was inserted cardboard sheet with 17,55 right-hand risk value and 16,51 left-hand risk value. Improvement proposed in this study was the design of the work method with rest time calculation and posture correction. Decreasing of OCRA index after improvement result was at 11,11% to 76,37%.
In a metal casting industry, Hanger Shot Blast KAZO machine plays a very vital role for blasting. The downtime equipment data for the last five years, 2013 to 2017, shows that the hanger shot blast KAZO is the machine which frequently encounters downtime with the number of 503,75 hours. As the only blasting machine with 2 (two) tons of load capacity, the issues of hanger shot blast KAZO affect to the targeted production process of company. Moreover, it increases risk of safety for the workers surround the machine. The purpose of this current research is to find out the reliability value of the item/ component of hover shot blast KAZO machine using Reliability Analysis method. The malfunction of its component is reviewed by FMEA (Failure Mode and Effect Analysis). While the risk assessment is obtained from RPN (Risk Priority Number) calculation -MTTF value and reliability value R(t). The result of this current study found that there are 21 malfunctions on hanger shot blast KAZO machine. MTTF analysis shows the highest MTTF value is 9195,324 hours for bearing impeller component and the lowest is 3498,997 hours for motor components. Meanwhile, reliability analysis shows that the largest reliability value with 0.999915 is encountered by motor contactor of crane, while with a value of 0.26385, hanger rotator motor contactor component encountered the lowest reliability value.
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