Design of Ergonomic Work Facilities

Oct 13, 2025 by recoveryshake.com 108 views

Introduction

Manual material handling in brick printing is a common practice in many industries, including the Nainggolan refinery, a UKM that produces bricks with clay raw materials. However, this practice poses significant health risks to workers, including complaints of pain in the shoulders, arms, and waist. The main source of these problems is the lack of ergonomic work facilities, which can lead to musculoskeletal disorders (MSDs) and other work-related injuries. This study aims to design ergonomic work facilities based on worker anthropometry to prevent pain and increase productivity in the Nainggolan refinery.

Background

The Nainggolan refinery produces more than 24,000 bricks per day, with workers manually moving bricks from the printing station to the cart. The weight of each brick is 28.8 kg, and workers carry out this task continuously for 8 hours per day. This manual material handling activity is the main source of problems in the printing station, with workers experiencing complaints of pain in the shoulders, arms, and waist. The lack of ergonomic work facilities is the primary cause of these problems, which can lead to MSDs and other work-related injuries.

Methodology

This study used a mixed-methods approach to collect data on the work posture and working conditions at the printing station. Interviews, questionnaires, and direct observations were conducted to gather information on the workers' experiences and perceptions of the work environment. The standard Nordic Questionnaire (SNQ) was used to assess the workers' musculoskeletal symptoms, while the Rapid Entire Body Assessment (Reba) was used to evaluate the risk level of MSDs. The analysis of the data showed that the work posture and working conditions at the printing station are not ergonomic, with workers experiencing high levels of pain and discomfort.

Results

The analysis of the data showed that the work posture and working conditions at the printing station are not ergonomic. The SNQ results showed that workers are in a very painful category on the left shoulder, right shoulder, right upper arm, left upper arm, right forearm, left arm, and waist. The Reba assessment showed a high risk level, with a value of 8-10, which means that workers need immediate improvement. The analysis of the recommended weight limit (RWL) and lifting index (LI) showed that the workload borne by workers exceeds the safe limit. The first operator RWL in the initial and ending situations was 9.87 kg and 6.52 kg, with a LI value of 1.46 and 2.21 respectively. The second operator RWL value in the initial and ending situations was 5.73 kg and 5.07 kg, with a successive LI value of 2.51 and 2.84.

Design of Ergonomic Work Facilities

Based on the analysis of the data, this study designed an ergonomic work facility using the principle of anthropometry. The design includes:

Roller Table

Size: 80 cm x 90 cm x 70 cm
Designed to help workers move bricks more easily and reduce the load on the back

Trolley

Height: 86.82 cm
Diameter of grip: 2.98 cm
Width: 45.95 cm
Designed to make it easier for workers to push carts and reduce loads on the arms

Cutting Tool

Diameter of grip: 2.98 cm
Designed to facilitate the cutting of bricks and reduce the load on the hand

Pallet

Size: 103 cm x 24 cm x 2 cm
Diameter of grip: 2.98 cm
Designed to facilitate lifting bricks and reducing the load on the back

Conclusion

The application of ergonomic work facilities is expected to reduce the risk of injury to workers, increase productivity, and create a healthier and more comfortable work environment in the Nainggolan refinery. The design of ergonomic work facilities based on worker anthropometry is a crucial step in preventing pain and increasing productivity in manual material handling in brick printing. The results of this study can be used as a reference for other industries that face similar challenges in maintaining the health and well-being of their workers.

Recommendations

Based on the findings of this study, the following recommendations are made:

The Nainggolan refinery should implement the designed ergonomic work facilities to reduce the risk of injury to workers and increase productivity.
The refinery should conduct regular training and education programs for workers on the proper use of ergonomic work facilities and the importance of maintaining a healthy and comfortable work environment.
The refinery should conduct regular assessments of the work posture and working conditions to identify areas for improvement and implement necessary changes.

Limitations

This study has several limitations that should be noted. The sample size was limited to 10 workers, and the study was conducted in a single industry. Future studies should aim to increase the sample size and conduct the study in multiple industries to increase the generalizability of the findings.

Future Research Directions

Future research should aim to:

Conduct a larger-scale study to increase the generalizability of the findings.
Conduct the study in multiple industries to increase the applicability of the findings.
Investigate the effectiveness of the designed ergonomic work facilities in reducing the risk of injury to workers and increasing productivity.
Investigate the impact of ergonomic work facilities on worker satisfaction and well-being.

Q: What is the main purpose of ergonomic work system design in manual material handling in brick printing?

A: The main purpose of ergonomic work system design in manual material handling in brick printing is to prevent pain and increase productivity by reducing the risk of injury to workers and creating a healthier and more comfortable work environment.

Q: What are the common problems faced by workers in manual material handling in brick printing?

A: The common problems faced by workers in manual material handling in brick printing include complaints of pain in the shoulders, arms, and waist due to the lack of ergonomic work facilities.

Q: What is the recommended weight limit (RWL) and lifting index (LI) in manual material handling?

A: The recommended weight limit (RWL) and lifting index (LI) are used to assess the risk of injury to workers in manual material handling. The RWL is the maximum weight that a worker can safely lift, and the LI is a measure of the risk of injury associated with lifting a particular weight.

Q: What are the benefits of ergonomic work system design in manual material handling in brick printing?

A: The benefits of ergonomic work system design in manual material handling in brick printing include reducing the risk of injury to workers, increasing productivity, and creating a healthier and more comfortable work environment.

Q: How can ergonomic work system design be implemented in manual material handling in brick printing?

A: Ergonomic work system design can be implemented in manual material handling in brick printing by designing and installing ergonomic work facilities, such as roller tables, trolleys, cutting tools, and pallets, that are tailored to the specific needs of workers.

Q: What are the key factors to consider when designing ergonomic work facilities for manual material handling in brick printing?

A: The key factors to consider when designing ergonomic work facilities for manual material handling in brick printing include the size and weight of the bricks, the frequency and duration of lifting, and the physical demands of the task.

Q: How can the effectiveness of ergonomic work system design be evaluated in manual material handling in brick printing?

A: The effectiveness of ergonomic work system design can be evaluated in manual material handling in brick printing by conducting regular assessments of the work posture and working conditions, monitoring worker injuries and illnesses, and conducting surveys to measure worker satisfaction and well-being.

Q: What are the potential challenges and limitations of ergonomic work system design in manual material handling in brick printing?

A: The potential challenges and limitations of ergonomic work system design in manual material handling in brick printing include the high cost of implementing ergonomic work facilities, the need for regular maintenance and repair, and the potential for workers to adapt to the new work environment and develop new habits that may not be as safe.

Q: How can ergonomic work system design be integrated into existing work processes and systems in manual material handling in brick printing?

A: Ergonomic work system design can be integrated into existing work processes and systems in manual material handling in brick printing by involving workers and supervisors in the design process, conducting regular training and education programs, and implementing changes in a phased and incremental manner.

Q: What are the potential long-term benefits of ergonomic work system design in manual material handling in brick printing?

A: The potential long-term benefits of ergonomic work system design in manual material handling in brick printing include reduced worker injuries and illnesses, increased productivity and efficiency, and improved worker satisfaction and well-being.