Perancangan material handling equipment yang ergonomi merupakan salah satu cara untuk mengatasi musculoskeletal disorders (MSDs). Hasil implementasi desain material handling equipment menunjukkan beberapa masalah antara lain tingkat keberasilan operator dalam menggunakan alat 57%, jumlah kesalahan penggunaan alat yang besar, terdapat keluhan operator terkait teknis alat, Hal tersebut menunjukkan perlu perbaikan pada desain produk. Pada penelitian ini perbaikan desain menggunakan metode pengembangan produk Ulrich Eppinger. Selanjutnya dilakukan pengujian hasil perbaikan dengan menggunakan usability testing dan fisiologi kerja, sehingga diperoleh perbandingan antara prototype material handling equipement improvement 1 dan prototype material handling equipment improvement 2 berdasarkan aspek usability produk dan ergonomi fisiologi kerja. Hasil penelitian ini adalah prototype material handling equipment yang mudah digunakan, efektif, efisien dan memuaskan pengguna. Berdasarkan analisis usability testing dan fisiologi kerja diperoleh hasil prototype material handling equipment improvement 2 memiliki waktu kerja, tingkat keberhasilan penggunaan alat, jumlah kesalahan penggunaan alat, keluhan pengguna terkait teknis alat yang lebih sedikit dibandingkan prototype material handling equipment improvement 1. Dari hasil usability questionare diperoleh rata-rata tanggapan penguna terhadap aspek learability 4.19, aspek efficiency 4.84, aspek memorability 4.61, aspek error 4.6, aspek satisfaction 5,03 dari skala likert 1-5. Selain itu berdasarkan analisis pengaruh alat terhadap fisiologi kerja operator terdapat penurunan persentase cardiovascular load kondisi exsisting 32% menjadi 20% pada kondisi menggunakan prototype material handling equipment improvement 2. Hal tersebut menunjukkan pototype material handling equipment improvement 2 dapat meningkatkan efektivitas dan efisiensi kerja operator.
Briquettes are solids that are produced through the process of compression and pressure application and if burned will produce a small amount of smoke. Briquette production is carried out using a hammer mill where the raw material for briquettes is charcoal which is then crushed into charcoal granules. The packaging process is still done manually using a shovel to fill the 50kg sack and then take it to the sewing machine. The worker's posture when using a shovel has a Rapid Entire Body Assessment (REBA) score of 12 so it has a high work risk of musculoskeletal disorders (MSDs) and requires immediate improvement. The working environment at the company produces pollutants, meaning that there is no capture container for the fall of charcoal grains from the hammer mill. Based on the existing problems, a redesign of the existing machine is needed. The proposed machine was designed using the Reverse Engineering method because the existing condition already uses the machine then the existing machine is decomposed to find out the components and functions of the existing machine to find alternative concepts. The ergonomic approach uses REBA and LBA to determine changes in worker posture and the forces acting in the human spine. The DEM approach was chosen to find out if the charcoal grains dropped from the hammer mill were successfully captured and to find out the flow of the charcoal grains. The results of the proposed machine design have a good impact on workers in the packaging process.
In this research, the working hours and posture of CNC (Computer Numerical Control) machine operators were investigated to determine the physical workload that they experienced during their daily work. Based on our observations, the operator works 8-hour regular shifts or 12-hour long shifts for 5 – 6 days a week. During these shifts, the operators work in front of the CNC machine while standing upright without any tools to rest. Preliminary research was conducted to evaluate these conditions the results show 13 out of 20 CNC machine operators complained about physical fatigue while working the CNC machines. It can also be concluded that the operators are experiencing excessive workload based on a workload assessment using the Quick Exposure Check (QEC) method. To solve this problem, a standing chair is designed with ergonomics in mind. The dimensions of the standing chair are based on the anthropometry of the CNC machine operators, which was never used before. The design process is conducted using the Theory of Inventive Problem Solving (TRIZ) methodology. Need statements from the CNC machine operators and design requirements from the stakeholders are converted into design specifications using TRIZ methodology. Parameters are determined to increase the capability of the existing design based on the design specifications. The result of this research is a standing chair that is suitable for the operator’s needs. Based on the analysis of the design result and the stress analysis simulation, it can be concluded a functional standing chair can be ergonomically designed with the TRIZ methodology.
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