Title: Ergonomics intervention with DMAIC methodology application - a case study in the food manufacturing industry

Authors: Nur Nadia Nadirah Yusuf; Shaliza Azreen Mustafa; Rosmaini Ahmad

Addresses: Faculty of Mechanical Engineering Technology, Universiti Malaysia Perlis (UniMAP), Puah Putra Campus, Arau, 02600, Perlis, Malaysia ' Advanced Manufacturing System Research Group, Faculty of Mechanical Engineering Technology, Universiti Malaysia Perlis (UniMAP), Puah Putra Campus, Arau, 02600, Perlis, Malaysia ' Advanced Manufacturing System Research Group, Faculty of Mechanical Engineering Technology, Universiti Malaysia Perlis (UniMAP), Puah Putra Campus, Arau, 02600, Perlis, Malaysia

Abstract: This study aims to assess the level of ergonomics risk factors (ERFs) in production workstations using ergonomics assessment tools and provide an appropriate solution to improve the safety and health of the workers. A systematic approach using define-measure-analyse-improve-control (DMAIC) methodology was applied. Initial assessment found that awkward posture was the main ERF emerging in the company. Under the Measure and Analyse phases, the rapid upper limb assessment (RULA) and rapid entire body assessment (REBA) tools were applied to further assess of the identified ERFs. Results found that the filling task is the highest risk condition. Improve phase involved improvements action based on simple invention using a wooden step stool to provide a neutral working posture and the REBA has showed the signs of low risk comparatively. Related recommendations based on hazard identification, risk assessment and risk control (HIRARC) were then given in the control phase for future work planning.

Keywords: ergonomics assessment; musculoskeletal disorders; MSD; DMAIC; RULA; REBA; food industry.

DOI: 10.1504/IJISE.2024.138163

International Journal of Industrial and Systems Engineering, 2024 Vol.47 No.1, pp.125 - 141

Received: 07 Mar 2022
Accepted: 29 May 2022
Published online: 30 Apr 2024 *

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