Mitigating Ergonomic Risks through Lean Ergonomics and Karakuri Kaizen Using NBM and RULA: A Case Study of Visual Inspection Operators in Automotive Manufacturing

Abdul Ajid; Adi Widya; Christa Pratiwi

doi:10.53697/emak.v7i1.3594

Authors

Abdul Ajid Universitas Pelita Bangsa
Adi Rusdi Widya Universitas Pelita Bangsa
Christa Dian Pratiwi Universitas Pelita Bangsa

DOI:

https://doi.org/10.53697/emak.v7i1.3594

Keywords:

Karakuri Kaizen, Lean Ergonomics, Musculoskeletal Disorders , Nordic Body Map, Rapid Upper Limb Assessment

Abstract

This research is aimed at the reduction of ergonomic risk factors and complaints of work-related musculoskeletal disorder (WMSDs) among visual inspection operators in the automotive component industry using the integration of Lean Ergonomics and Karakuri Kaizen. A case study was carried out at PT Kanemitsu SGS Indonesia focusing on five visual inspection operators. Ergonomic risk factors were analyzed using the Nordic Body Map (NBM) to evaluate musculoskeletal discomfort and the Rapid Upper Limb Assessment (RULA) for working postures. Primary assessments revealed the presence of significant ergonomic risk factors which resulted in the average NBM score of 62.6 and RULA score of 7 which indicates the presence of risk factors regarding working posture and action required correction on an urgent basis. Ergonomic modifications were accomplished by workstation redesigning based on the principles of anthropometry, which is the science of design and proportions of the human body, layout optimization, and integration of gravity-assisted Karakuri mechanisms to alleviate manual lifting and forward bending. The post-intervention assessment revealed the ergonomic risk factors have been significantly minimized and the NBM score and RULA score are now 28.8 and 3 respectively. Also, there was more than 75% reduction in the frequency of forward bending, which decreased from more than 80 occurrences per shift to less than 20. As such, the application of the two concepts in tandem suggests they may provide a viable and cost-effective solution to the balance of ergonomics and sustainable improvement to the comfort and productivity of the systems workers use in the automotive industry manual visual inspection systems.

Downloads

Download data is not yet available.

References

Adiyanto, O., Mohamad, E., Jaafar, R., Ma’ruf, F., Faishal, M., & Anggraeni, A. (2022). Application of Nordic Body Map and Rapid Upper Limb Assessment for assessing work-related musculoskeletal disorders: A case study in small and medium enterprises. International Journal of Integrated Engineering, 14(4), 10–19. https://doi.org/10.30880/ijie.2022.14.04.002

Anggraeni, D. L. (2015). Keluhan musculoskeletal disorders pada pekerja mekanik unit produksi TCW di PT GMF AeroAsia tahun 2015 [Undergraduate thesis, Program Studi Kesehatan Masyarakat].

Ashary Aznam, S., Mardi Safitri, D., & Dwi Anggraini, R. (2017). Ergonomi partisipatif untuk mengurangi potensi terjadinya work-related musculoskeletal disorders. Jurnal Teknik Industri, 7(2). https://doi.org/10.25105/jti.v7i2.2213

Ayu Paramudita, P. H. L., Amaliah, L., Ayunitasanti, R. D., et al. (2024). Perkembangan indeks produksi industri manufaktur 2023. Badan Pusat Statistik. https://www.bps.go.id/id/publication/2024/08/30/4cbfc30e81404b7b48e1172b

Brito, M., Ramos, A. L., Carneiro, P., & Gonçalves, M. A. (2018). Integration of lean manufacturing and ergonomics in a metallurgical industry. Proceedings of the International Symposium on Occupational Safety and Hygiene, 2, 21–31. https://doi.org/10.24840/2184-0954

Colim, A., Morgado, R., Carneiro, P., Costa, N., Faria, C., Sousa, N., Rocha, A., & Arezes, P. (2021). Lean manufacturing and ergonomics integration: Defining productivity and wellbeing indicators in a human–robot workstation.

Dul, J., & Weerdmeester, B. (2008). Ergonomics for beginners: A quick reference guide (3rd ed.). CRC Press. https://doi.org/10.1201/9781420077520

Corlett, E. N., & Wilson, J. R. (Eds.). (1995). Evaluation of human work (2nd ed.). Taylor & Francis.

Eliasson, K., Wiklund, A. F., Dahlgren, G., Hellman, T., Svartengren, M., Nyman, T., & Lewis, C. (2022). Ergonomists’ experiences of executing occupational health surveillance for workers exposed to hand-intensive work: A qualitative exploration. BMC Health Services Research, 22, 1–12. https://doi.org/10.1186/s12913-022-08601-2

Exegens Team. (2019). Karakuri kaizen: The step before Industry 4.0. Exegens. https://exegens.com/karakuri-kaizen-step-industry-4-0

Gürsoy Özcan, A. (2022). Application of REBA and Karakuri Kaizen techniques to reduce ergonomic risk levels in a workplace. Mühendislik Bilimleri ve Tasarım Dergisi, 10(4), 1430–1444. https://doi.org/10.21923/jesd.957691

Imansuri, F., Jyestha, R., Dahmar, H., & Syarifudin, A. (2024). Design of material handling equipment in the bending process using Karakuri Kaizen method: An analysis of working posture. 14(2), 77–89.

McKendrick, J. (2023, September 27). We can’t find enough skilled workers—Can automation fill the gaps? Forbes. https://www.forbes.com/sites/joemckendrick/2023/09/27/we-cant-find-enough-skilled-workers-can-automation-fill-the-gaps/

Kartika, A. D. C., & Mukhtar, M. N. A. (2023). Penerapan RULA dan REBA dalam mengatasi kelelahan operator mesin roll bottom. Heuristic, 13–24. https://doi.org/10.30996/heuristic.v20i1.8867

Kumar, H. V., Annamalai, S., & Bagathsingh, N. (2021). Impact of lean implementation from the ergonomics view: A research article. Materials Today: Proceedings, 46, 9610–9612. https://doi.org/10.1016/j.matpr.2020.07.113

Kurganov, V., Sai, V., Gryaznov, M., & Dorofeev, A. (2021). The emergence and development of lean thinking in transport services. Transportation Research Procedia, 54, 309–319. https://doi.org/10.1016/j.trpro.2021.02.077

Lynn, M., & Corlett, N. (1993). RULA: A survey method for the investigation of work-related upper limb disorders. Applied Ergonomics, 24(2), 91–99.

Machado, D. C., Rodrigo, B. C., & Gutierrez, J. T. (2023). Ergonomic improvement to reduce the risk of musculoskeletal disorders in a furniture production workshop. Advances in Transdisciplinary Engineering, 35, 549–555. https://doi.org/10.3233/ATDE230080

Mozzi, V., Catia, P., & Principi, M. (2019). Ergolean: Quando ergonomia e lean manufacturing integrano il management e la sicurezza aziendale. Journal of Advanced Health Care, 2(1), 64–66. https://doi.org/10.36017/jahc20202157

Pheasant, S., & Haslegrave, C. M. (2018). Bodyspace: Anthropometry, ergonomics and the design of work (3rd ed.). CRC Press. https://doi.org/10.1201/9781315375212

Primasari, M. S., & Kurnianingtyas, C. D. (2022). Analisis postur kerja dan manual material handling pada aktivitas pemindahan material di bengkel bubut BP. Jurnal PASTI, 16(2), 124. https://doi.org/10.22441/pasti.2022.v16i2.001

Tarwaka, & Bakri, S. H. A. (2016). Ergonomi untuk keselamatan, kesehatan kerja, dan produktivitas. Uniba Press.

Widya, A. R., Sari, P. A., & Anggara, M. H. A. (2023). Analisa risiko ergonomi untuk mengurangi cedera otot pada proses barcode material menggunakan metode Nordic Body Map dan REBA. Jurnal Teknik Industri, 4(1), 64–73. https://doi.org/10.37366/jutin.v4i01.2061

World Health Organization. (2020). Musculoskeletal conditions. https://www.who.int/news-room/fact-sheets/detail/musculoskeletal-conditions

غلامحسین، ث. (2002). Macroergonomics: Theory, methods, and applications. Lawrence Erlbaum Associates.