Design Development of a Pallet Stacker through Integration ...eprints.utem.edu.my/4689/1/Design_Development_Of_A_Pallet_Stacker... · iii ABSTRACT Material handling device (MHD) is

UNIVERSITI TEKNIKAL MALAYSIA MELAKA

Design Development of a Pallet Stacker through

Integration of Ergonomic Assessment and Quality

Function Deployment (QFD) at Machine Shop in

UTeM

Report submitted in accordance with the requirements of the Universiti Teknikal

Malaysia Melaka for the Bachelor’s in Manufacturing Engineering

(Manufacturing Management) with Honors.

By

Mohd Fahmi Bin Baharuddin

Faculty of Manufacturing Engineering

April 2008

oval

UTeM Library (Pind.1/2005)

UNIVERSITI TEKNIKAL MALAYSIA MELAKA (UTeM)

BORANG PENGESAHAN STATUS TESIS*

JUDUL: DESIGN DEVELOPMENT OF A PALLET STACKER THROUGH INTERGRATION OF ERGONOMIC ASSESSMENT AND QUALITY FUNCTION DEPLOYMENT

(QFD) AT MACHINE SHOP IN UTeM

SESI PENGAJIAN: 2007/2008

Saya MOHD FAHMI BIN BAHARUDDIN

mengaku membenarkan tesis (PSM/Sarjana/Doktor Falsafah) ini disimpan di Perpustakaan Universiti Teknikal Malaysia Melaka (UTeM) dengan syarat-syarat kegunaan seperti berikut:

1. Tesis adalah hak milik Universiti Teknikal Malaysia Melaka. 2. Perpustakaan Universiti Teknikal Malaysia Melaka dibenarkan membuat salinan

untuk tujuan pengajian sahaja. 3. Perpustakaan dibenarkan membuat salinan tesis ini sebagai bahan pertukaran

antara institusi pengajian tinggi.

4. **Sila tandakan (√)

SULIT

TERHAD

√

TIDAK TERHAD

(Mengandungi maklumat yang berdarjah keselamatan atau kepentingan Malaysia yang termaktub di dalam

AKTA RAHSIA RASMI 1972)

(Mengandungi maklumat TERHAD yang telah ditentukan

oleh organisasi/badan di mana penyelidikan dijalankan)

(TANDATANGAN PENULIS)

Alamat Tetap: NO 160, Jln Sri Intan, Taman Sri Intan II, 36400 Hutan Melintang, Perak. Tarikh: 24 March 2008

Disahkan oleh:

(TANDATANGAN PENYELIA)

Cop Rasmi: Tarikh: _______________________

* Tesis dimaksudkan sebagai tesis bagi Ijazah Doktor Falsafah dan Sarjana secara penyelidikan, atau disertasi bagi pengajian secara kerja kursus dan penyelidikan, atau Laporan Projek Sarjana Muda (PSM). ** Jika tesis ini SULIT atau TERHAD, sila lampirkan surat daripada pihak berkuasa/organisasi berkenaan dengan menyatakan sekali sebab dan tempoh tesis ini perlu dikelaskan sebagai SULIT atau TERHAD.

i

DECLARATION

I hereby, declared this report entitled “Design Development of Pallet Stacker through

Integration of Ergonomic Assessment and Quality Function Deployment at Machine

Shop in UTeM” is the result of my own research except as cited in references.

Signature : ………………………………………..

Author’s Name : …………………………………………

Date : …………………………………………

ii

APPROVAL

This report submitted to the senate of Universiti Teknikal Malaysia Melaka (UTeM) and

has been as partial fulfillment of the requirements for the Bachelor of Manufacturing

Engineering (Manufacturing Management) with Honors. The members of the

supervisory committee are as follow:

………………………………

MR. ISA BIN HALIM

Main Supervisor

Faculty of Manufacturing Engineering

Universiti Teknikal Malaysia Melaka

iii

ABSTRACT

Material handling device (MHD) is an equipment used to help workers in manufacturing

activities especially in transferring goods and materials. The advantage of MHD is it can

reduce the load of lifting task thus minimize the potential risk of musculoskeletal

problems. This study presents the design and development of MHD through integration

of ergonomics assessment and Quality Function Deployment (QFD). The specific

objectives of this study are to determine the safe lifting limit, redesign the MHD i.e.

pallet stacker and evaluate the effectiveness of the proposed design. To achieve

mentioned objectives, Rapid Upper Limb Assessment (RULA) was used to evaluate the

working posture; Quality Function Deployment (QFD) was utilized to redesign the pallet

stacker; Push and pulling analysis was adopted to determine the lifting limit of worker.

Based on result obtained, the RULA score and push pulling analysis shows the injuries

happened which neck, arm, and lower back while are working. Meanwhile, based on the

QFD results some part of pallet stacker which handle, platform, wheel should be

improve in order to reduce risk of injuries. From conducted study, the author concluded

that the approaches are able to adopted redesign a pallet stacker that saves to the worker.

iv

ABSTRAK

Alat bantuan bagi pengantara adalah alat yang digunakan bagi membantu pekerja di

dalam industri pembuatan terutamanya memindahkan barangan dan alatan.

Kelebihannya ialah ia dapat mengurangkan berat untuk mengangkat barangan dan juga

mengurangkan potensi bagi pekerja untuk mendapat kecederaan. Tujuan kajian ini

adalah membincangkan mengenai reka bentuk dan pembangunan bagi alat bantuan

pengatara melalui ergonomik intergrasi dan ’Quality Function Deployment’ (QFD)

didalam industri. Objektif kajian ini adalah untuk menentukan tahap mengangkat yang

selamat, mereka bentuk semula ’pallet stacker’ dan menilai keberkesanan reke bentuk

yang baru. Untuk mencapai objektif kajian ini, perisian RULA, QFD dan analisis ‘Push

and Pulling’ telah digunakan. Daripada keputusan kajian yang di lakukan dengan

menggunakan perisian RULA dan ‘Push and Pulling’, sebahagian anggota badan seperti

leher, pinggang, lengan di dapati ketika bekerja. Manakala, dari keputusan QFD yang

dijalankan, sebahagian bahagian ’pallet stacker’ perlu diubah suai antaranya platform,

pemegang tangan dan roda. Daripada analisis yang dijalankan, keputusan kajian

menunjukkan bahawa pelaksanaan kajian ini dapat mengurangkan potensi untuk

mendapat kecederaan ketika menggunakan alat pengantara tersebut.

v

DEDICATION

For my beloved parents:

Baharuddin Bin Ibrahim

Latifah Binti Mohammed Dawood

And for my adored brothers and sister:

Norwahidah Binti Baharuddin

Mohd Fadhli Bin Baharuddin

Mohd Anas Bin Baharuddin

Mohd Ainul Alwi Bin Baharuddin

And my inspiration:

Noor Juliani Ngah

vi

ACKNOWLEDGEMENT

Bismillahhirrahmanirrahim…

First of all, I would like to express my very special thank to my beloved parents,

Mr. Baharuddin Bin Ibrahim and Madam Latifah Binti Mohammed Dawood for their

full support, and guidance which I receive from them helps me to be strong and patience to

finish up this study. Without their prayer and blessing, I would possibly not finish this study.

Then, with my great respect, I would like to thank to Mr. Isa Bin Halim who has

excellently supervised me, given good and existing suggestions and criticism to the

process of the work and motivate me in a good way which makes me improve in this

study.

Not forgotten, I would like to thank to all my friends for continuously supporting,

motivating and helping me in completing this study.

Lastly, to all people that involve in this study, thanks for your cooperation and kindness.

Mohd Fahmi Bin Baharuddin

vii

TABLE OF CONTENTS

Declaration…………………………………………………………………………...i

Approval……………………………………………………………………………..ii

Abstract……………………………………………………………………………..iii

Abstrak……………………………………………………………………………...iv

Dedication…………………………………………………………………………...v

Acknowledgement…………………………………………………………………..vi

Table of Contents…………………………………………………………………..vii

List of Figures……………………………………………………………………….xii

List of Tables…………………………………………………………………….....xvi

List of Abbreviations, Symbols, Specialized Nomenclature………………………xvii

1.INTRODUCTION

1.1 Background…………………………………………………………………….1

1.2 Problem Statement……………………………………………………………..3

1.3 Objectives of study..…………………………………………………………...4

1.4 Scope and limitation of study………………………………………………….5

1.5 Potential benefits of study.…………………………………………………….5

1.6 Report Outline…………………………………………………………………7

2. LITERATURE REVIEW

2.1 Introduction……………………………………………………………….….8

2.2 Design……………………………………………………………………......8

2.2.1 Design criteria…………………………………………………………....9

2.2.2 Design of stacker………………………………………………………...10

2.3 Material Handling Device (MHD)………………………………………… .11

2.3.1 Definition of material handling device………………………………….12

2.3.2 Material handling device task……………………………………….......13

2.3.3 The proper design of Material handling device………………………....14

2.4 Ergonomics…………………………………………….……………………15

viii

2.4.1 Definition of ergonomics……………………….……………………….16

2.4.2 Ergonomics in industry………………………………………………….16

2.5 Manual material handling…………………………………………………...18

2.5.1 Introduction to manual material handling……………………….............19

2.5.2 Definition of manual material handling………………………………....20

2.5.3 Principle of manual material handling…………………………………..20

2.5.4 Fundamental approach the manual material handling…………………..21

2.5.4.1 Biomechanical approach…………………………………………..22

2.5.4.2 Physiological approach……………………………………………22

2.4.5.3 Psychophysical approach………………………………………….23

2.5.5 Manual handling risk factor……………………………………………..23

2.5.6 Work related musculoskeletal disorders………………………………...24

2.5.6.1 Work related musculoskeletal disorders …………………………25

2.5.6.2 Musculoskeletal disorders (MSDs) activities…………………....25

2.5.6.3 Load handling…………………………………………….………26

2.5.7 Lifting safety……………………………………………………….…...27

2.5.8 Pushing and pulling……………………………………………………..28

2.5.9 Observation method for ergonomics assessments……………………...30

2.5.9.1 Rapid Upper Limb Assessment (RULA)………………………....30

2.5.9.2 Rapid Entire Body Assessment (REBA)…………………………31

2.5.9.3 NIOSH lifting equation 1991 …………………………………….31

2.5.9.4 Lifting index (LI)…………………………………………………31

2.5.9.5 Recommended weight limit (RWL)………………………………32

2.6 Direct method assessment…………………………………………………...33

2.6.1 Electromyography (EMG)……………………………………………...33

2.6.2 Electrogoniometers……………………………………………………..33

2.6.3 Lumbar Motion Monitoring (LLM)…………………………………….34

2.6.4 Carry analysis…………………………………………………………...35

2.6.5 CAD/CATIA…………………………………………………………....36

2.7 Quality Function Deployment (QFD)……………………………………….37

2.7.1 Definition of Quality Function Deployment (QFD)…………………….39

2.7.2 House of quality…………………………………………………………39

ix

2.7.2.1 Foundation of house of quality (planning matrix)…………………..39

2.7.2.2 Steps to build House of Quality……………………………………..40

a) Step 1 - Customer requirement (Voice of Customer)…………….40

b) Step 2 - Technical descriptors (Voice of Engineer)……………...41

c) Step 3 - Relationship between customer requirements and

technical descriptors(trade-off)…………………………43

d) Step 4 - Interrelationship between technical descriptors…………44

e) Step 5 - Prioritized customer requirements……………………….46

2.6 Previous study ………………………………………………………………47

3. METHODOLOGY

3.1 Introduction………………………………………………………………….50

3.2. Methodology………………………………………………………………...51

3.2.1 Determine the safe lifting limit regarding to manual material handling

activities………….……………………………………………………...51

3.2.2 Redesign current pallet stacker in order to improve Working Posture….53

3.2.3 Evaluate the effectiveness of proposed design of stacker ………………58

3.2.4 Summarization of methodologies……………………………………….59

4. CASE STUDY

4.1 Background of case study.…………………………………………………….60

4.2 Machine shop laboratory………………………………………………………61

4.3 Material handling device used………………………………………………...62

4.4 Pallet stacker…………………………………………………………………..63

4.5 Assessment of case study……………………………………………………...64

4.5.1 Design of pallet stacker……………………………………………………64

4.5.2 Job activities when used the pallet stacker………………………………..64

4.5.3 Assessment of working posture…………………………………………...65

4.6 Case studies – Transferring the metal from the storage onto Laser

Cutting Machine…………………………………………….......67

x

5. RESULT AND ANALYSIS

5.1 Introduction…….……………………………………………………………...71

5.2 Determine the safe lifting limit regarding to manual material handling

activities.………………………………………………………………………72

5.3 Redesign current pallet stacker to improve working posture.……………..…..75

5.3.1 Questionnaire result……………………………………………………….75

5.3.2 QFD analysis………………………………………………………………84

5.3.2.1 Characteristic of customer requirement……………………………..84

5.3.3 Develop the House of Quality (HOQ)…………………………………….91

5.4 Evaluate the effectiveness of proposed design of Pallet stacker……………….93

5.4.1 Redesign of pallet stacker regarding from the QFD analysis……………...94

5.5 Analysis for current design…………………………………………………….97

5.5.1 Lift the object by using the current design of pallet stacker result analysis.99

5.5.2 Pushing process to move the object by using the pallet stacker analysis….99

5.5.3 Pulling process to move the object by using the current design of pallet

stacker analysis…………………………………………………………...102

5.2.4 The analysis for transfer the raw material from the pallet stacker into

laser cutting machine..…………………………………………………....105

5.5. Analysis for propose design………………………………………………….106

5.5.1 Lift the object by using the new design of pallet stacker result analysis…107

5.5.2 Pull the object by using the new design of pallet stacker result analysis...109

5.5.3 Pull the object by using the new design of pallet stacker result analysis...112

5.5.4 Analysis to transfer process the raw material from the pallet stacker

into laser cutting machine………………………………………………...114

5.6 Comparison between the current design and new design…………………….116

6. DISCUSSION

6.1 Introduction…….…………………………………………………………….121

6.2 To determine the safe lifting limit regarding to manual materials handling

activities…………………………………………………………………...…122

6.3 To redesign current Pallet Stacker in order to improve working posture……124

xi

6.3.1 RULA analysis in redesign the current pallet stacker……………………124

6.3.2 Lift the object…………………………………………………………….124

6.3.3 Pull the pallet stacker………………………………………………...…..125

6.3.4 Push the pallet stacker……………………………………………………125

6.3.5 Transfer the raw material from the pallet stacker into laser cutting

machine………………………………………………………………......126

6.3.6 Push and Pull analysis for pushing and pulling pallet stacker…………...126

6.3.7. The workers needed regarding to the design of pallet stacker for

material handling device activities……………………………………....127

6.3.8 Design improves for the current of pallet stacker………………………..127

6.4 Evaluate the effectiveness of the design……………………………………..130

6.4.1 Lift the object process……………………………………………………131

6.4.2 Pull the pallet stacker process…………………………………………....131

6.4.3 Push the pallet stacker process…………………………………………..132

6.4.4 Process to transfer the material using pallet stacker……………………..133

6.5 Comparison from the working posture result………………………………..133

7. CONCLUSION

7.1 Introduction…….…………………………………………………………….139

7.2 To determine the safe lifting limit regarding to manual materials handling

activities…………………………………………………………………...…139

7.3 Redesign current Pallet Stacker in order to improve working posture……....140

7.4 Evaluate the effectiveness of proposed design of pallet stacker……………..141

8. RECOMMENDATION………………………………………………………..142

8.1 Recommendation for design………………………………………………….142

8.2 Recommendation for ergonomic activities and assessment…………………..142

REFERENCES……………………………………………………………………144

APENDICES

Appendix A

Appendix B

xii

LIST OF FIGURE

1.1 Report outline………………………………………………………………...7

2.1 The whole body and part of the stacker in order to redesign the current

design of pallet stacker …………………………………………………..…10

2.2 The percentage of the most common worker complaints reported with

respect to health and safety………………………………..………………..17

2.3 The key factors that must be considered when designing a safe and

productive pushing/pulling task, ……………………………………………29

2.4 The horizontal and vertical position of the hands relative to the subject’s

toes at the origin of the lift ………………………………………………….33

2.5 How to wear the Lumbar Motion Monitor ………………...……………….35

2.6 House of Quality…………………………………………………………….46

3.1 Determination of working posture using RULA analysis and table of

Result for ergonomics activities will presented by using the Catia

Software.……………………………………………..……………….……..53

3.2 Table for data of working posture by using RULA analysis…….………….54

4.1 Surface grinding machine…………………………………………………...61

4.2 Lathe machine ……………………………………………………….……...61

4.3 Horizontal band saw…………………………………………..…………….61

4.4 Boring machine ……………………………………….…………………….61

4.5 2 Wheel cart…………………………………..……………………………..62

4.6 4 Wheel cart…………………………………………………………………62

4.7 Hand pallet truck……...……………………………………………………..62

4.8 Pallet stacker……………………………………………………………….. 62

4.9 Pallet stacker…………………………………..…………………………….63

4.10 Goniometry tool …………………………………………………………….65

4.11 Dimension of anthropometry to measure in RULA analysis………………..65

4.12 Lifting task…………………………………………………………………..67

4.13 Press jack task……………………………………………………………….68

4.14 Push the pallet stacker task………………………………………………….69

4.15 Pull the pallet stacker……………………………………………………….70

xiii

4.16 Transfer the object task……………………………………………...………70

5.1 Working posture and lifting task ……...…………………………………….72

5.2 The percentages of respondent like the current design of the pallet stacker..77

5.3 The percentages of respondent wish to improve or redesign ………………77

5.5 The percentages of believe that the pallet stacker is helping to lift a heavy

load and huge object………………………………………………….….....78

5.7 The percentages of respondent got the pain history while handling the

pallet stacker…………………………………………………………….…79

5.8 The percentages of respondent have any difficulties while handling the

pallet stacker………………………………………………………………..79

5.9 The percentages of pain detected when used the pallet stacker……. ………80

5.10 Statistic for platform (arm) part …………………………………………….81

5.11 Statistic for platform (arm) part …………………………………………….81

5.12 Statistic for wheel part ……………………………………………………...82

5.13 Statistic for hydraulic part system…………………………………………...82

5.14 Body diagram for stability of pallet stacker…………………………………85

5.15 Body diagram for beam deflection………………………………………….87

5.16 Body diagram for pushing process………………………………………….88

5.17 Body diagram for pulling process…………………………………………...89

5.18 Body diagram for lift load process…………………………………………..90

5.19 QFD result analysis to redesign and improve the current of pallet stacker…91

5.20 The current pallet stacker that been design through the QFD,

RULA analysis………………………………………………………………94

5.21 Body diagram for new force of pushing…………………………………….96

5.22 Body diagram for new force of pulling……………………………………..97

5.23 RULA analysis result for the case study by using the current design of pallet

stacker.,,……………………………………………………………………..98

5.24 RULA analysis for left sided body for lift the object……………………….99

5.25 RULA analysis for right sided body for lift the object……………………...99

5.26 The working posture pushing processes with object loaded……………….100

5.27 The data result for pushing process (right side)……………………………101

5.28 The data result for pushing process (left)……………………………….…102

xiv

5.29 Pushing and pulling analysis……………………………………………….102

5.30 Pulling process by using Catia software…………………...………………103

5.31 Data result for pulling process (right)……………………………………...103

5.32 Data result for pulling process (left)…………………………………...…..104

5.33 Data result for push and pulling analysis…………………………………..104

5.34 The working posture to transfer the object………………………………...105

5.35 Data result for working posture (left)……………………………………...106

5.36 Data result for working posture (right)…………………………………….106

5.37 RULA analysis result for the case study by using the current design of

pallet stacker……………………………………………………………….108

5.38 The result of working posture after new design of pallet stacker (left)……108

5.39 The result of working posture after new design of pallet stacker (right)….109

5.40 The working posture of manikin for new design of pallet stacker………...110



5.43 The RULA analysis result for pulling process by using the new design of

pallet stacker……………………………………………………………….111

5.44 The result of working posture after new design of pallet stacker (right)…..112


5.46 The working posture to transfer the object……………………………...…113



6.1 The layout that does not ergonomic and must be modify immediately

so that it can decrease the risk of injuries to all user………………………123

6.2 The new design of pallet stacker…………………………………………...130

6.3 Comparison between current design and new design based on RULA

score for right side………………………………………………………....133


score for left side…………………………………………………………..134


score for right side……………………………………..…………………..134

xv


score for left side…………………………………………………………...135


score for left side…………………………………………………………..136


score for left side…………………………………………………………...136


score for left side……………………………………………………….…..137


Score for right side…………………………………………………………137

xvi

LIST OF TABLES

3.1 Table for data of working posture by using RULA analysis………………..54

4.1 The anthropometric data from the technicians…………….………………...66

5.1 Frequency Multiplier ..………………………………..…………………….73

5.2 Coupling Multipliers………………………………………………………...73

5.3 Technical specifications of current design of pallet stacker………………...76

5.4 The mean result and importance to customer in order to know which one

the critical part of improvement……………………………………….……83

5.6 Technical specifications of new design of pallet stacker…………………..95

5.7 The comparison of ergonomic analysis between the current design and

proposed new design of pallet stacker using RULA analysis……………..117

5.8 The comparison of ergonomic analysis between the current design and

proposed new design of pallet stacker using RULA analysis……………...119

5.9 The maximum acceptable initial maximum and acceptable sustained force

for pushing process………………………………………………………..120

5.10 That the value of pulling can accommodate force when pulling the

pallet stacker……………………………………………………………….120

5.11 Demonstrate the value scores those found from RULA analysis for

pushing process…………………………………………………………….121

6.1 Third teen part of improvement needed base on the questionnaire………..128

6.2 The result of QFD analysis………………………………………………...128

xvii

LIST OF ABBREVIATIONS, SYMBOLS, SPECIALIZED

NOMENCLATURE

MHD - Material handling device

CTD - Cumulative trauma disorder

NIOSH - National Institute of Safety and Health

NLE - NIOSH Lifting Equation

MMH - Manual material handling

MSD - Musculoskeletal disorder

RULA - Rapid Upper Limb Assessment Analysis

REBA - Rapid Entire Body Assessment Analysis

QFD - Quality Function Deployment

OSHA - Occupational Safe and Health Act

CATIA - Computer Aided Tree Dimensional Interactive Application

LLM - Lumbar Motion Monitor

EMG - Electroginiometer

CAD - Computer Aided Design

CAM - Computer Aided Manufacturing

CAE - Computer Aided Engineering

1

CHAPTER 1

INTRODUCTION

This chapter provides information on background of study, problem statement and

objective of study. Besides, this chapter also describes the scope and limitation of study,

potential benefits from the study that may significant to student, authorities, or related

organizations. The outline of conducted study also presented in this chapter.

1.1 Background of Study

Manufacturing industry is a critical industry in Malaysia as it contributes economy

source nowadays. The development and implementation of manufacturing was

responsible for one of the great advances in human history, and the industrial revolution.

To stay competitive in global market, the manufacturing sector in our country needs to

improve the productivity through upgrading of its primary production technology.

Manufacturing firms also must achieve a degree of innovative capability in managing

production operations, processes and advance to use new equipment. Through that,

many factors can helps to achieve the new phenomenon after the industrial revolution in

our country. For example, the uses of machining and material handling device that can

help the production system working properly and smoothly.

Material handling device (MHD) is a good example to help the workers in

manufacturing industries especially in ergonomics application. The advantages of MHD

in industry to replace repetitive lifting task has created a new sources of potential

musculoskeletal problem. Material handling device is capable to move heavy objects,

2

such as large waste containers and other large objects that requiring mechanical

assistance. The ergonomic material handling device can be used with neutral postures of

the back, shoulders, wrists and knees, thereby reducing potential injury to the user.

For example, the pallet stacker is a common a material handling device used in

manufacturing industries. The purpose of pallet stacker used to transfer or move the

objects to others location. It is can help the workers to transfer or move heavy and large

objects with easily. Besides, the weight load and larger objects can decrees the

consumption of the pallet lifting ability and the workers get the injuries with easily. In

this case, the suitable design of material handling device can helps workers that will

effectively reduced the musculoskeletal disorders work through the ergonomics

applications. Ergonomics programs seek to identify and correct factors that negatively

impact the physical health of their workers. Ergonomics programs seek to maximize the

involvement of the workers in this process based on the simple fact that a worker is an

expert on his or her job. Ergonomics also relies on actively involving workers in

implementing ergonomic knowledge, procedures and changes with the intention of

improving working conditions, safety, productivity, and quality.

In this project, the purposes are to create a new design about the material handling

device applications especially in industrial field and also as a reference to solve the

ergonomic problems. Consequently, it can be useful to improve their works and reduce

injuries and musculoskeletal disorders injuries problems towards them. This chapter

provides an overview of the research project titled Design Development of Pallet

Stacker through Integration of Ergonomic Assessment and Quality Function

Deployment (QFD) in Machine Shop in UTeM.

3

1.2 Problem Statement

In industry scenario, heavy lifting has been identified as a major factor for the

development of back injuries (Marras et al., 1993; Hildebrant, 1987). Hence, primary

prevention of musculoskeletal complaints requires reduction in physical load, for

example by implementation of ergonomic improvements (Schneider, 2001). From this

problem, the MHD is used to prevent the occupational injuries such as low back injuries

and low back pain. According to the (Myung, CJ et al., 2004), mass production service

in industry have replace a burden of manual material handling on workers. To reduce the

problem, management has provided manual vehicles, such as carts, truck, wheelbarrows

and so on. However, the others problems related to fortify the manual handling device

are:

a) Moving large pieces of furniture is a physically demanding task. Little has

been done to decrease the strain on the body during these manual lifting

tasks. (Jessica K. Paskiewicz et al., 2007)

b) The three major injuries resulting from pushing and pulling trolleys and carts

in food and drink industries were strains, sprains, and bruises (Health and

Safety Executive, 2002).

c) In other reason, lifting is a very complex task that requires the activation and

coordination of the entire body (Chen, 2000; van Dieen et al., 1996).

4

1.3 Objectives of Study

In order to solve above mentioned problems, this project tries to achieve following

objectives:

a) To determine the safe lifting limit regarding to manual materials handling

activities.

An observation was conducted to determine the safe lifting limits among

the workers who involved in manual materials handling activities.

b) To redesign current pallet stacker in order to improve working posture.

Redesign the current pallet stacker is device to improve the working

posture. The purpose is to ensure a worker is safe while handling the

material using redesigned pallet stacker.

c) To evaluate the effectiveness of the proposed design of pallet stacker.

The effectiveness of the proposed designed of pallet stacker will be done

by comparing findings of current design and improved design.

Documents

Design Development of a Pallet Stacker through Integration ...eprints.utem.edu.my/4689/1/Design_Development_Of_A_Pallet_Stacker... · iii ABSTRACT Material handling device (MHD) is