ERGONOMIC OPTIMIZATION OF MACHINING

OPERATIONS OF POWER TRANSMISSION SHAFTS

PROJECT REPORT
Submitted by

AJITH JAMES
SJC16MEAP01

To
The APJ Abdul Kalam Technological University
in partial fulfilment of the requirements for the award of the Degree
of
Master of Technology
in
Advanced Manufacturing and Production Management

Department of Mechanical Engineering

St. Joseph’s College of Engineering & Technology
Palai

MAY, 2018
 ERGONOMIC OPTIMIZATION OF MACHINING
OPERATIONS OF POWER TRANSMISSION SHAFTS

PROJECT REPORT
Submitted by

AJITH JAMES
SJC16MEAP01

To
The APJ Abdul Kalam Technological University
in partial fulfilment of the requirements for the award of the Degree
of
Master of Technology
in
Advanced Manufacturing and Production Management

Department of Mechanical Engineering

St. Joseph’s College of Engineering & Technology
Palai

MAY, 2018
 DECLARATION

I undersigned hereby declare that the project report “ERGONOMIC OPTIMIZATION

OF MACHINING OPERATIONS OF POWER TRANSMISSION SHAFTS”, submitted

for partial fulfilment of the requirements for the award of degree of Master of Technology

of the APJ Abdul Kalam Technological University, Kerala is a bonafide work done by

me under supervision of Mr. Tom Zacharia. This submission represents my ideas in my

own words and where ideas or words of others have been included. I have adequately and

accurately cited and referenced the original sources. I also declare that I have adhered to

ethics of academic honesty and integrity and have not misrepresented or fabricated any

data or idea or fact or source in my submission. I understand that any violation of the

above will be a cause for disciplinary action by the institution and/or the University and

can also evoke penal action from the sources which have thus not been properly cited or

from whom proper permission has not been obtained. This report has not been previously

formed the basis for the award of any degree, diploma or similar title of any other

University.

Palai

01-May, 2018

AJITH JAMES
 DEPARTMENT OF MECHANICAL ENGINEERING
ST. JOSEPH’S COLLEGE OF ENGINEERING & TECHNOLOGY,
PALAI

CERTIFICATE
This is to certify that the report entitled ERGONOMIC OPTIMIZATION
OF MACHINING OPERATIONS OF POWER
TRANSMISSION SHAFTS submitted by AJITH JAMES to the APJ Abdul
Kalam Technological University in partial fulfilment of the requirements for the award
of the Degree of Master of Technology in Advanced Manufacturing and Production
Management, Mechanical Engineering is a bonafide record of the project work carried
out by him under our guidance and supervision. This report in any form has not been
submitted to any other University or Institute for any purpose.

Internal Supervisor PG Coordinator

Mr. Tom Zacharia Mr. Tom Zacharia
Assist.Prof in Mech. Engg. Assist.Prof in Mech. Engg.

Head of the Department

Dr. Binoy Baby
Dept. of Mech. Engg.
 ACKNOWLEDGEMENT

First and foremost, I shall thank God Almighty who gave me the inner strength, resource
and ability to complete my work successfully, without which all my efforts would have been in
vain.
I am extremely happy to mention a great word of gratitude to Dr. Binoy Baby, Head of
the Department of Mechanical Engineering, St. Joseph’s College of Engineering & Technology,
and Palai for providing me with all facilities for completing this project.

I express my heartfelt thanks to Mr. Tom Zacharia (PG Coordinator, AMPM) for his
helpful feedback and timely assistance. I wish to place on records my ardent and earnest gratitude
to him for all the help and guidance rendered as my project guide.

I convey my sincere thanks to all other staff members for their help and encouragement. I
thank all my friends who have helped me during the work, with their inspiration and co-operation.
I truly admire my parents for their constant encouragement and enduing support, which were
inevitable for the success of this venture. Once again I convey my gratitude to all those who
directly or indirectly influenced me for the successful completion of the work.

Ajith James

ii
 ABSTRACT
Workstation efficiency and operator satisfaction are two main factors which influence the
overall productivity of a production unit. Considering ergonomic factors while designing a
workstation will help to develop a better environment for working and will help to avoid unsafe
working conditions. This project was conducted in a machining station to find out the various
factors which may result in serious health issues to the operator and reduction of productivity.
According to the study various modifications are made by considering ergonomic factors and
results show that efficiency and operator satisfaction have been improved after implementing
the recommendations.

ii
 CONTENTS
Title Page No.
Abstract…………………………………………………………………ii
List of figures…………………………………………………………...v
List of tables……………………………………………………………vi

1. Introduction………………………………………………………..01
1.1 Objective………………………………………………………01
1.2 Scope…………………………………………………………..01
1.3 Overview………………………………………………………01
2. Literature review…………………………………………………..02
2.1 Ergonomics…………………………………………………….02
2.1.1 Why is Ergonomics important…………...…....….……...03
2.2 Anthropometry……………………………………....………....03
2.2.1 Standard Anthropometric postures…………...………….04
2.2.2 Working posture…………………………...…...………..04
2.2.3 Vision and posture of the head and neck……………...…05
2.2.4 Working height…………………………………………..06
2.2.5 Posture and strength……………………………………..06
2.3 Musculoskeletal disorders (MSD)…………………………….07
2.3.1 Causes of work related MSDs…………………………..07
2.3.2 Body parts most affected by MSDs……………………..08
2.4 Ergonomic principles in workstation design………………….10
2.4.1 Body height and working height………………………..11
2.4.2 Work area……………………………………………….11
2.4.3 Reach zone……………………………………………...12
2.4.4 Range of vision…………………………………………12
2.5 Benefits of using ergonomics in workstation design…………12
2.6 Rapid upper limb assessment (RULA)……………………….13
2.6.1 Applying RULA………………………………………..14
3. Methodology……………………………………………………...20
3.1 Sample and data collection…………………………………...20
3.2 Operator motion study………………………………………..20
 3.2.1 Collection of raw materials…...………………………...21
3.2.2 Loading and unloading of parts from machine...……….21
3.2.3 Visual inspection and measurements…….……………..21
3.2.4 Applying rust oil and putting protective covering……...21
3.2.5 Transferring finished parts……………………………...21
3.3 Analysis of results…………………………………………….21
4. Discussions………………………………………………………..26
4.1 Height gauge positioning……………………………………..26
4.2 Manual chip removal…………………………………………28
4.3 Manual transfer of parts………………………………………30
4.4 Oiling of finished parts……………………………………….32
4.5 Arrangement of gauges……………………………………….34
4.6 Modified work table…………………………………………..37
5. Conclusion………………………………………………………...38

REFERENCES………………………………………………………..39

LIST OF PUBLICATIONS..………………………………………….40
 LIST OF FIGURES

Title Page No.

2.1 Comfortable visual area………………………………………05
2.2 Upper arm score...………………………………………….....15
2.3 Lower arm score………………………………………………15
2.4 Wrist score………………………………………………….....16
2.5 Neck score………………………………………………….....16
2.6 Trunk score……………………………………………………17
2.7 RULA score sheet……………………………………………..18
3.1 Table and height gauge………………………………………..23
3.2 Height measuring……………………………………………...23
3.3 Oiling tray……………………………………………………..25
4.1 Current table specification…………………………………….26
4.2 View in current table…………………………………………..26
4.3 Modified table specifications………………………………….27
4.4 View in modified table………………………………………...27
4.5 Modified table…………………………………………………27
4.6 Height checking in modified table…………………………….27
4.7 Trolley for material transfer…………………………………...31
4.8 Trolley specifications………………………………………….32
4.9 Modified oiling mechanism……………………………………33
4.10 Modified oiling mechanism specifications…………………...34
4.11 Gauge stand…………………………………………………...35
4.12 Gauge stand specifications……………………………………36
4.13 Modified work table…………………………………………..37

v
 LIST OF TABLES

Title page no
3.1 RULA score for height checking……………………………22

3.2 RULA score for manual part transfer…………………….....23

3.3 RULA score for manual chip removal………………………24

4.1 RULA score for height checking in modified table…………28

4.2 Average time loss due to manual chip removal……………..29

4.3 Monthly production efficiency………………………………29

4.4 Weight of a batch of products………………………………..30

vi
 CHAPTER 1

INTRODUCTION

Workstations and operators are the key factors in a manufacturing unit. Quality of the workstations
will directly influence the productivity of the operators. It is therefore critical that they are designed
to be as ergonomic, flexible and efficient as possible. The main purpose of ergonomic design is to
make the workstation suitable for operators of different anthropometric dimensions. It is a known
fact that the ergonomically ideal layout of workstations and workplaces not only stimulates the
efficient manufacture of the product, but also has direct benefits with respect to reducing the
psychological demands placed on employees.

1.1 OBJECTIVE
To study and optimize secondary machining operations of Power transmission shaft production
process.

1.2 SCOPE
 To make a detailed study of the performance parameters in the production process of power
transmission shaft
 To develop an ergonomic workstation and efficient work practices to reduce the rejection
of parts due to handling damages
 To conduct motion study of the operator to avoid nonproductive movements

1.3 OVERVIEW

The following pages contain the data collected about various ergonomics factors of the
workstation, operator motion study and details about the various modifications made on the
workstation to improve the efficiency.

1
 CHAPTER 2

LITERATURE REVIEW

2.1 ERGONOMICS
Ergonomics is defined as the study of work. More specifically, ergonomics is the science of
designing the job to fit the worker, rather than physically forcing the worker’s body to fit the job.
Adapting tasks, work stations, tools, and equipment to fit the worker can help reduce physical
stress on a worker’s body and eliminate many potentially serious disabling work related
musculoskeletal disorders (MSDs). Ergonomics utilize varies scientific disciplines including
physiology, biomechanics, psychology, anthropometry, industrial hygiene, and kinesiology
(Jeffrey E. Fernandez).

An ergonomist evaluates the demands of a specific task with reference to the capacity of
workers to perform the task over a certain time period. When developing a particular job design,
the demands of the task would ideally be held within the capacity of a fixed percentage of the
working population (so that 75 to 95 per cent of the population is accommodated). When the task
demands of an existing job are such that it is beyond the capacity of this predetermined percentage
of the population, then the work, procedures, and/or work tools should be redesigned in order to
accommodate the predetermined percentage of the working population. If the accommodated
percentage is unacceptable (e.g., below 75 per cent) and redesign is not possible, then the final
alternative is to place workers so that only those whose capacity exceeds the task demands are
allowed to perform the task (Jeffrey E. Fernandez).

An ergonomic approach for the design of industrial workstations is the attempt to achieve
an appropriate balance between the worker’s capabilities and worker’s requirements as well as
provide the worker with physical and mental well-being, job satisfaction and safety. Over the last
two decades, ergonomics researchers and practitioners have devoted considerable resources to
solve the problems associated with the ergonomic design of the working environment. Designers
of workplaces have usually three major tasks: one, integrating information about processes, tools,
machines, parts, tasks, and human operators; two, satisfying design constraints which often
conflict; and three, generating a design acceptable to all parties involved.

2
2.1.1 Why Is Ergonomics Important?
Industries increasingly require higher production rates and advances in technology to remain
competitive and stay in business. As a result, jobs today can involve:
• Frequent lifting, carrying, and pushing or pulling loads without help from other workers
or devices;
• Increasing specialization that requires the worker to perform only one function or
movement for a long period of time or day after day;

• Working more than 8 hours a day;

• Working at a quicker pace of work, such as faster assembly line speeds; and

• Having tighter grips when using tools.

These factors especially if coupled with poor machine design, tool, and workplace design or the
use of improper tools create physical stress on workers’ bodies, which can lead to injury (U. S.
Government).

2.2 ANTHROPOMETRY
Anthropometry is the branch of the human sciences that deals with body measurements:
particularly with measurements of body size, shape, strength and working capacity. Factors
which affect anthropometric measurements include gender, ethnicity, growth and development,
secular trend, ageing, social class, and occupation, as well as clothing and personal equipment.
Each person's anthropometric measurement is compared to values observed in the general
population and expressed as percentiles. Percentile is defined as a set of divisions that produce
exactly 100 equal parts in a series of continuous values. In ergonomic design, one can use
anthropometric data in three different ways. The first is designing for a range (the
smallest to the largest, usually from the 5th percentile to the 95th percentile), such as the design of
adjustable height chairs based on popliteal height. The second is designing for the extremes (the
smallest or the largest, usually for the 5th percentile or the 95th percentile), such as the design of
the doorpost height for the largest person's stature (plus ample clearance) or the design of a shelf
for the smallest person's functional reach. The third is designing for an average. This method is
only acceptable when one is using the workplace for a very short duration. This method is usually
avoided by ergonomists, as it does not accommodate a large segment of the user population. An

3
example is designing work surface heights in a bank for customers' elbow height (Jeffrey E.
Fernandez).

2.2.1 Standard Anthropometric Postures

There are mainly two standard postures are in there; Standard standing posture and standard siting
posture.
In the standard standing posture the subject stands erect, pulling himself up to his full height
and looking straight ahead, with his shoulders relaxed and his arms hanging loosely by his sides.
He stands free of walls, measuring instruments, etc.

In the standard sitting posture the subject sits erect on a horizontal, flat surface, pulled up
to his full height and looking straight ahead. The shoulders are relaxed, with the upper arms
hanging freely by the sides and the forearms horizontal (i.e. the elbows are flexed to a right angle).
The height of the seat is adjusted (or blocks are placed under the feet) until the thighs are horizontal
and the lower legs are vertical (i.e. the knees are flexed to a right angle). Measurements are made
perpendicular to two reference planes. The horizontal reference plane is that of the seat surface.
The vertical reference plane is a real or imaginary plane which touches the back of the
uncompressed buttocks and shoulder blades of the subject. The seat reference point (SRP) lies at
the point of intersection of these two planes and the median plane of the body (i.e. the plane that
divides it equally into its right and left halves) (John R Wilson).

2.2.2 Working Posture

The posture that a person adopts when performing a particular task is determined by the
relationship between the dimensions of the person’s body and the dimensions of the various items
in his or her workspace. The extent to which posture is constrained in this way is dependent upon
the number and nature of the connections between the person and the workspace. These
connections may be either physical (seat, worktop, etc.) or visual (location of displays, etc.). If the
dimensional match is inappropriate the short- and long-term consequences for the well-being of
the person may be severe.

Posture may be defined as the relative orientation of the parts of the body in space. To
maintain such an orientation over a period of time, muscles must be used to counteract any external
forces acting upon the body (or in some minority of cases internal tensions within the body). The

4
most ubiquitous of these external forces is gravity. Muscle as a tissue responds badly to prolonged
static mechanical loading. (The same is probably true of other soft tissues, and even perhaps of
bone, but the physiology of these cases is much less well understood.) Static effort restricts the
flow of blood to the muscle. The chemical balance within the muscle is disturbed, metabolic waste
products accumulate and the condition of ‘muscular fatigue’ supervenes. The person experiences
a discomfort which is at first vague but which subsequently develops into a nagging pain until it
becomes a matter of some urgency that relief is sought by a change of position (John R Wilson).

2.2.3 Vision and the Posture of the Head and Neck

The visual demands of a task and the location of visual displays are important not only in
themselves, but also because they largely determine the posture of the head and neck. Only the
central part of the visual field is sufficiently sensitive for demanding visual tasks such as reading
text or recognizing a face. The area of foveal vision, as this central region is called, is limited to a
solid angle of some 5° about the line of central fixation. Visual work demands
that the foveal regions of both eyes be directed convergent upon the task. Furthermore, the lenses
of the eyes must accommodate (focus) to the appropriate distance. The processes of direction and
convergence of gaze are integrated with accommodation by a set of flexes so finely tuned that we
are unaware of their existence until such times as they break down by reason of age or inebriation.

Figure 2.1 Comfortable visual area

Comfortable zone for the location of visual displays extends from the horizontal line of
sight downwards to an angle of 30° and that the optimal line of sight is somewhere in the middle

5
of this zone. Given that some modest degree of neck flexion is acceptable, this could be extended
a further 15°.

2.2.4 Working Height

The height above the ground at which manual activities are performed by the standing person is a
major determinant of that person’s posture. If the working level is too high the shoulders and upper
limbs will be raised, leading to fatigue and strain in the muscles of the shoulder region (trapezius,
deltoid, levator scapulae, etc.). If any downward force is required in the task the upper limbs will
be in a position of poor mechanical advantage for providing it. This problem may be avoided if
the working level is lower.
The following recommendations concerning working height are widely quoted

 for manipulative tasks involving a moderate degree of both force and precision 50–100 mm
below elbow height;

 for delicate manipulative tasks (including writing) 50–100 mm above elbow height (wrist
support will generally be necessary);

 for heavy manipulative tasks (particularly if they involve downward pressure on the
workpiece)100–250 mm below elbow height;

 for lifting and handling tasks between knuckle height and elbow height ;

 for hand-operated controls (e.g. switches, levers, etc.) between elbow height and shoulder
height.

2.2.5 Posture and Strength

Studies in which strength is measured in different positions commonly show that the differences
between conditions (i.e. between working postures) are greater than the differences between
individuals. Strength is dependent on posture, first for reasons of physiology, and second for
reasons of simple mechanics.
The function of a muscle is to exert tension between its points of bony attachment and by
doing so to exert a torque or moment about the joint (or joints) that the muscle crosses. The
capacity of a muscle to exert tension is dependent upon its length, which in turn is dependent upon
the position (i.e. angle) of the joint across which it acts. This defines the angle-torque relationship

6
of the joint. In general, muscles are able to exert their greatest tension in their ‘outer range’, that
is, at or near their position of maximum length.

2.3 MUSCULOSKELETAL DISORDERS (MSD)

MSDs, or musculoskeletal disorders, are injuries and disorders of the soft tissues (muscles,
tendons, ligaments, joints, and cartilage) and nervous system. They can affect nearly all tissues,
including the nerves and tendon sheaths, and most frequently involve the arms and back.
These painful and often disabling injuries generally develop gradually over weeks, months,
and years. MSDs usually result from exposure to multiple risk factors that can cause or exacerbate
the disorders, not from a single event or trauma such as a fall, collision, or entanglement. MSDs
can cause a number of conditions, including pain, numbness, tingling, stiff joints, difficulty
moving, muscle loss, and sometimes paralysis. Frequently, workers must lose time from work to
recover; some never regain full health. These disorders include carpal tunnel syndrome, tendinitis,
sciatica, herniated discs, and low back pain. MSDs do not include injuries resulting from slips,
trips, falls, or similar accidents (U. S. Government).

2.3.1 Causes of Work-Related MSDS

Work-related MSDs occur when the physical capabilities of the worker do not match the
physical requirements of the job. Prolonged exposure to ergonomic risk factors can cause
damage a worker’s body and lead to MSDs. Conditions that are likely to cause MSD problems
include the following:
• Exerting excessive force;

• Excessive repetition of movements that can irritate tendons and increase pressure on
nerves;

• Awkward postures, or unsupported positions that stretch physical limits, can compress nerves
and irritate tendons;

• Static postures, or positions that a worker must hold for long periods of time, can restrict blood
flow and damage muscles;

•Motion, such as increased speed or acceleration when bending and twisting, can increase the
amount of force exerted on the body;

7
 • Compression, from grasping sharp edges like tool handles, can concentrate force on
small areas of the body, reduce blood flow and nerve transmission, and damage tendons and
tendon sheaths;

• Inadequate recovery time due to overtime, lack of breaks, and failure to vary tasks
can leave insufficient time for tissue repair;

• Excessive vibration, usually from vibrating tools, can decrease blood flow, damage
nerves, and contribute to muscle fatigue.

• Whole-body vibration, from driving trucks or operating subways, can affect skeletal
muscles and cause low-back pain; and

• Working in cold temperatures can adversely affect a worker’s coordination and manual
dexterity and cause a worker to use more force than necessary to perform a task.

These risk factors, either alone or in combination, can subject workers’ shoulders, arms,
hands, wrists, backs, and legs to thousands of repetitive twisting, forceful, or flexing motions
during a typical workday. To contribute to MSDs, however, these risk factors must be present
for a sufficient duration, frequency, or magnitude (U. S. Government).

The main risk factors of musculoskeletal disorders are

 Force
 Repetition
 Awkward postures
 Static postures
 Quick motions
 Compression or contact stress
 Vibration
 Cold temperatures

2.3.2 Body Parts Most Affected By MSDS

MSDs can affect nearly all tissues in the human body: the nerves, tendons, tendon sheaths, and
muscles. The most frequently affected areas of the body are the arms and the back. Tendon

8
disorders such as tendinitis, tenosynovitis, De Quervain’s disease, trigger finger, and carpal tunnel
syndrome are the most common occupational MSDs associated with the arm.
Tendon disorders are very common and often occur at or near the joints where the tendons
rub against other tendons, ligaments, or bones. The most frequently noted symptoms of tendon
disorders are a dull aching sensation over the tendon, discomfort with specific movements, and
tenderness to touch. Recovery is usually slow, and the condition may easily become chronic if the
physical stresses causing the problem are not eliminated or reduced.

Another MSD that has received increased attention in recent years is carpal tunnel
syndrome, or CTS, which affects the hands and wrists. CTS is the compression and entrapment
of the median nerve where it passes through the wrist into the hand—in the carpal tunnel. The
median nerve is the main nerve that extends down the arm to the hand and provides the sense of
touch in the thumb, index finger, middle finger, and half of the fourth, or ring, finger. When
irritated, tendons housed inside the narrow carpal tunnel swell and press against the nearby median
nerve. The pressure causes tingling, numbness, or severe pain in the wrist and hand—often felt
while sleeping. The pressure also results in a lack of strength in the hand and an inability to make
a fist, hold objects, or perform other manual tasks. If the pressure continues, it can damage the
nerve, causing permanent loss of sensation and even partial paralysis. CTS develops in the hands
and wrists from repetitive and forceful manual tasks performed without time to recover. Any
worker whose job demands a lot of repetitive wrist, hand, and arm motion—not necessarily
forceful—could develop CTS.

Another MSD that accounts for a significant loss of productivity and large compensation
costs to industry is back injury. Workers cite back disorders most often, after the common cold
and flu, as reasons for missing work. The most common back problems are pulled or strained
muscles, ligaments, and tendons. More serious disorders involve spinal discs. More than half the
work force experience back pain at least once during a lifetime. When repetitive pulling and
straining injures back muscles or ligaments, the back muscles, discs, and ligaments can become
scarred and weakened and lose their ability to support the back. This makes additional injuries
more likely.

9
2.4 ERGONOMIC PRINCIPLES IN WORKSTATION DESIGN
The term “ergonomics” is a combination of the Greek words “ergon” – work and “nomos” law.
The most important factors for designing work equipment are the working height, proper sizing of
the reach zones and required leg room, as well as definition of the appropriate range of vision. All
of these dimensions are derived from a “standardized” body height. Every workplace must be
designed for a certain height range and not for one particular height of person. The aim when
designing every workplace is to accommodate a range of heights.
Some ergonomics principles that should be applied to the workplace, whether in an industrial or
an office environment, include the following:

 Aim at dynamic work, avoid static work (work where there is no movement). Static work
or static loading of the muscles is inefficient and accelerates fatigue. Static work can occur
when the workplace is too high or too low, when holding a weight in one's arms for an
extended period, or when there is constant bending of the back to perform a task.
 Adjust work surface heights to the size (anthropometry) of the worker and the type of task
performed (precision, light assembly, or heavy manual).
 Work within 30 per cent of one's maximum voluntary contraction (strength). Avoid
overloading of the muscular system.
 Place primary controls, devices, and workpieces within the normal working area.
Secondary controls should be placed within the maximum working area so as to reduce
extended reaches and fatigue.
 Strive for best mechanical advantage of the skeletal system.
 Work with both hands. Do not use one hand (non-preferred hand) as a biological holding
device.
 Hands should move in symmetrical and opposite directions.
 Use the feet as well as the hands.
 Design knowing the capacity of the fingers. Do not overload the fingers.
 Use gravity. Do not oppose it to dispose of unbreakable products.
 Avoid unnatural posture. Bend the handle of the tool not the wrist.
 Permit change of posture. Maintain a proper sitting posture.
 Counter-balance tools when possible to reduce the weight and forces.

10
  Accommodate the large individual and give him or her sufficient room.
 Use bins with lips for storage and manual retrieval of small parts instead of boxes. Incline
containers so as to reduce awkward postures of the body.
 Train the individual to use the workplace, facility and equipment properly (Jeffrey E.
Fernandez).

The main criteria’s that must be considered while designing workstation are:

(1) Foot and leg room, depth and adjustment range of the footrest
(2) Size and variation of workpiece dimensions
(3) Occurring forces and weights
(4) Changing types of equipment and insert heights
(5) Greatly varying vision distances
(6) Local specifications (deviating body heights, legal requirements, etc.)
(7) Aspects related to methods, safety, and efficiency.

2.4.1 Body Height and Working Height

Manual workstations must accommodate a wide range of body heights to ensure that the largest
percentage of the population is covered. The optimum working height is based on the body height
range and the type of activity to be performed. The average optimum working height for average
requirements is 1125 mm for sit-down/stand-up workstations. Height-adjustable workstations are
the most flexible solution for dealing with extremely varied workpiece/component dimensions and
large differences in employee heights. The concept permits changes in posture, which reduces
stress and increases performance.

2.4.2 Work Area

The aim is for the distance of employee from the front edge of workbench to be as small as
possible. The distance to the working area influences the following: position of the arms, viewing
distance and inclination of the head. The work area height should always be between 800 mm and
1500 mm. The following rules must be observed:
 Avoid work above the heart (over 1500 mm): Otherwise, the circulation of blood and
oxygen to the muscles is reduced, which leads to a drop in performance

11
  Work that requires bending (below 800 mm) exerts employees disproportionately and
should be avoided
 Promote dynamic activities: static manual work (such as holding an object continuously)
inhibits the circulation of blood and oxygen to the muscles. This can lead to a drop in
performance and processing quality
 Allow for alternating physical exertion: for example, through sit-down/stand-up
workstations or job rotation. Alternating physical exertion reduces stress on the employee
and increases performance
 Minimize exertion: for example, through the use of manual roller sections or lifting aids,
as well by selecting lighter weight materials.

2.4.3 Reach Zone

All containers, equipment, and operating elements must be easily accessible and arranged in the
anatomic/physiological range of movement for the employee. All reach distances should be as
short as possible to avoid redundant, non-value- added movements. Grab containers and
parts containers that are in direct reach of the employee are ideal. Torso rotations and shoulder
movements, particularly when under exertion (with weights ≥ 1 kg), should be avoided whenever
possible.

2.4.4 Range Of Vision

For optimal workstation design, it’s important to follow recommendations on proper ergonomics
for vision. The following aspects must be taken into account during planning:
 Avoid unnecessary eye and head movements
 Implementing vision distances that are as identical as possible eliminates refocusing
 Avoid fastening locations not visible to the worker (Andrea LESKOVA).

2.5 BENEFITS OF USING ERGONOMICS IN WORKSTATION DESIGN

Providing a workplace free of ergonomic hazards can do the following:
 Lower injury rates as MSD incidences go down;

• Increase productivity by making jobs easier and more comfortable for workers;

• Improve product quality because fewer errors will be made when using automated

processes that demand less physical effort;

12
 • Reduce absences because workers will be less likely to take time off to recover from muscle

soreness, fatigue, and MSD-related problems;

• Reduce turnover as new hires are more likely to find an ergonomically designed job within
their physical capacity;

• Lower costs as workers’ compensation and other payments for illness and replacement

workers go down;

• Improve worker safety;

• Increase worker comfort;

• Reduce worker fatigue; and

• Improve worker morale (U. S. Government).

2.6 RAPID UPPER LIMB ASSESSMENT (RULA)

RULA (rapid upper limb assessment) is a survey method developed for use in ergonomics
investigations of workplaces where work-related upper limb disorders are reported. This tool
requires no special equipment in providing a quick assessment of the postures of the neck, trunk
and upper limbs along with muscle function and the external loads experienced by the body. The
RULA ergonomic assessment tool considers biomechanical and postural load requirements of job
tasks/demands on the neck, trunk and upper extremities. A single page worksheet is used to
evaluate required body posture, force, and repetition. Based on the evaluations, scores are entered
for each body region in section A for the arm and wrist, and section B for the neck and trunk. After
the data for each region is collected and scored, tables on the form are then used to compile the
risk factor variables, generating a single score that represents the level of MSD risk.

The method uses diagrams of body postures and three scoring tables to provide evaluation
of exposure to risk factors. The risk factors under investigation are those described by McPhee’ as
external load factors. These included:

13
  numbers of movements;

 static muscle work;

 force;

 work postures determined by the equipment and furniture;

 time worked without a break

In an effort to assess the first four external load factors described above (number of movements,
static muscle work, force and postures), RULA was developed to:

1. provide a method of screening a working population quickly, for exposure to a likely risk
of work- related upper limb disorders;
2. identify the muscular effort which is associated with working posture, exerting force and
performing static or repetitive work, and which may contribute to muscle fatigue;
3. Give results which could be incorporated in a wider ergonomics assessment covering
epidemiological, physical, mental, environmental and organizational factors, and
particularly to assist in fulfilling the assessment requirements of the UK Guidelines on the
prevention of work-related upper limb disorders.

RULA was developed without the need for special equipment. This provided the
opportunity for a number of investigators to be trained in doing the assessments without additional
equipment expenditure. As the investigator only requires a clipboard and pen, RULA assessments
can be done in confined workplaces without disruption to the workforce. Those who are trained to
use it do not need previous skills in observation techniques although this would be an advantage
(Lynn McAtamney).

2.6.1 Applying RULA

In RULA method the body is divided into segments which forms two groups: A and B. Group A
includes the upper and lower arm and wrist while Group B includes the neck, trunk and legs.
This ensures that the whole body posture is recorded so that any awkward or constrained
postures of the legs, trunk or neck which might influence the postures of the upper limb are
included in the assessment.

14
 The range of movement for each body part is divided into sections and these sections are
numbered so that the number 1 is given to the range of movement or working posture where the
risk factors present are minimal. Higher numbers are allocated to parts of the movement range
with more extreme postures indicating an increasing presence of risk factors causing load on the
structures of the body segment. This system of scoring each body part posture provides a sequence
of numbers which is logical and easily remembered.

Group A Figure 2, 3, 4 shows the diagrams for scoring the posture of the body parts in
Group A, which are the upper arm, lower arm and wrist, with a section to record the pronation or
supination occurring (called ‘wrist twist’).

Figure 2.2 Upper arm score (Lynn McAtamney)

The ranges for the lower arm are:

 1 for 60-100” flexion;

 2 for less than 60” or more than 100” flexion.

If the lower arm is working across the midline of the body or out to the side then the posture
score is increased by 1.

Figure 2.3 Lower arm score (Lynn McAtamney)

15
The guidelines for the wrist are:

 1 if in a neutral position;
 2 for O-15” in either flexion or extension;
 3 for 15” or more in either flexion or extension.

If the Wrist is in either radial or ulnar deviation then the posture score is increased by 1.

Figure 2.4 Wrist score (Lynn McAtamney)

Pronation and supination of the wrist (wrist twist) are defined around the neutral posture are
scored:

 1 if the wrist is in mid-range of twist;

 2 if the wrist is at or near the end of range of twist.

Group B the posture ranges for the neck are given as

Figure 2.5 Neck score (Lynn McAtamney)

 1 for O-10” flexion;

 2 for N-20” flexion;

 3 for 20” or more flexion;

 4 if in extension.

16
 If the neck is twisted these posture scores are increased by 1. If the neck is in side-bending
then the score is increased by 1.

Figure 2.6 Trunk score (Lynn McAtamney)

The ranges for the trunk are:

 1 when sitting and well supported with a hip-trunk angle of 90” or more;

 2 for O-20” flexion;

 3 for 20-60” flexion;

 4 for 60” or more flexion.

If the trunk is twisting the score is increased by 1. If the trunk is in side-bending, the score is
increased by 1.

The leg posture scores are defined as:

 1 if the legs and feet are well supported when seated with weight evenly balanced;
 1 if standing with the body weight evenly distributed over both feet, with room for
changes of position;
 2 if the legs and feet are not supported or the weight is unevenly balanced.

Recording the posture score: The assessment commences by observing the operator
during several work cycles in order to select the tasks and postures for assessment. Selection may
be made of the posture held for the greatest amount of the work cycle or where highest loads occur.
As RULA can be conducted quickly, an assessment can be made of each posture in the work cycle.
When using RULA, only the right or left side is assessed at a time. After observing the operator it

17
may be obvious that only one arm is under load; however, if undecided, the observer would assess
both sides.

Figure 2.7 RULA score sheet [11]

Using Figure 2, 3, 4 the observer records the posture scores for the upper arm, lower arm, wrist
and wrist twist in the column of boxes marked A on the left side of the score sheet (Figure 7).
Similarly, using Figure 5, 6 the posture scores for the neck, trunk and legs are calculated and
recorded in the column of boxes marked B on the score sheet.

Muscle use and force scores: A scoring system was developed to include the additional
load on the musculoskeletal system caused by excessive static muscle work, repetitive motions
and the requirement to exert force or maintain an external load while working. These scores are
calculated for each of the groups A and B and recorded in the appropriate boxes on the score sheet.

18
  Score A + muscle use and force scores for group A = Score C

 Score B + muscle use and force scores for group B = Score D

The third stage of RULA is to incorporate both score C and score D into a single grand
score whose magnitude provides a guide to the priority for subsequent investigations. Each
possible combination of score C and score D was given a rating, called a grand score, of l-7 based
upon the estimated risk of injury due to musculoskeletal loading.
The requirements for action into which the grand scores are divided is summarized into Action
leve1 as follows:
(1) Action level I
A score of 1 or 2 indicates that posture is acceptable if it is not maintained or repeated for
long periods.
(2) Action level 2
A score of 3 or 4 indicates that further investigation is needed and changes may be required.
(3) Action level 3
A score of 5 or 6 indicates that investigation and changes are required soon.
(4) Action level 4
A score of 7 indicates that investigation and changes are required immediately (Lynn
McAtamney).

19
 CHAPTER 3

METHODOLOGY

3.1 SAMPLE AND DATA COLLECTION

This study was focused on the workers from the automotive spare parts production unit of
Sundaram Fastners Ltd. Pvt.,Hosur. The people working in the first shift were considered for study
including both male and female operators. The main data were obtained through personal interview
and direct observations. Each person was personally interviewed to understand the level of
satisfaction in their jobs and also to find out the tasks were difficult for them. After this continuous
observation and analysis of their work practices were done.
Initially operator motion study has been conducted and this is analyzed for any inefficient
motion or work practices. By repeated observation incorrect work practices or inefficient
workstation conditions are determined. For the selected operations RULA method is used. Those
operations which reported ‘investigate and implement change’ is analyzed further and proper
modifications are made to avoid MSDs.

3.2 OPERATOR MOTION STUDY

Operations in all the machines have mainly five steps, they are:
1. Collection of raw material
2. Loading and unloading of parts from machine
3. Visual inspection and measurements
4. Applying rust oil and putting protective covering
5. Transferring finished parts

In the first step parts to be machined are collected from corresponding stations, which may
be forging output or output from CNC machining operation. Then to perform the next machining
operation, it is loaded to the machine and the machining operation is carried out according to the
coding given on the machine. After the machining process it is taken out from the machine and
next part is loaded. The currently produced part is taken for dimensional and visual checking. After
inspection the part is dipped in the rust oil and protective covering is given for certain products

20
and kept in special carrier boxes. After each box is completely filled it is moved to a stacking
section and kept in batches.

While observing the various operations, the following findings are made.

3.2.1 Collection of Raw Material

 In the machining- 1 operation input materials are not taken in batches, parts are carried in
hands, 3 or 4 pieces at a time. This increases the amount of motion of the operator, resulting
in waste of time and energy.
 Some operators take parts in batches, more than 15 pieces in a tray, manually. This is a very
dangerous practice and has a chance of causing musculoskeletal disorders

3.2.2 Loading and Unloading Of Parts from Machine

 Part is loaded for subsequent operations, and unloaded once the operation is completed
 For five machines chip is removed manually, resulting in loss of time and chance of
accidents is also high.
3.2.3 Visual Inspection and Measurements
 Inspection is carried out after placing the part on a fixture
 Position of the height gauge is inconvenient. Studies
 Gauges are placed without any orientation or order
3.2.4 Applying Rust Oil and Putting Protective Covering
 Rust oil is applied to finished parts and some parts are provided with a protective covering
 Product craton is used as oiling can, results in soaking of oil on hands
 For some machines rust oil can is not provided, so the operator needs to move to next
machine or skip the oiling process

3.2.5 Transferring Finished Parts

 Parts ready for shipment are transferred to conveyor on pallet
 Manually transferring the parts will result in musculoskeletal disorders

3.3 ANALYSIS OF RESULTS

According the operator motion study it is concluded as operations in all the machines have mainly
five steps.In the first step, parts to be machined are collected from corresponding stations, which
may be forging output or output from CNC machining operation. Then to do the corresponding

21
machining operation it is loaded to the machine and the machining operation is carried out
according to the coding given on the machine. Then after the machining process it is taken out
from the machine and next part is clamped on to the machine. Then the currently produced part is
taken for dimensional and visual checking. After the operator inspection the part is dipped in the
rust oil and protective covering is given for certain products and kept in special carrier boxes. After
each box is completely filled it is moved to a stacking section and kept in batches.
According to the detailed analysis of the motion study 4 major issues were identified for
modification.

1. Height of inspection table

Position of height is too low so that the operator has to bend down to take the reading.
According to the ergonomic standards the dial which shows the measurement should come
within ±30° of the visual angle of the viewer. Currently the angle of vision is more than 60°
and the operator has to bend down to take the reading. Since all the parts produced has to be
checked for overall length the operator has to bend for more than 200 times a day. Therefore
the chance of back pain is high.
In order to check the severity of the problem assessment using RULA worksheet has
been done. Table 1 presents the different categories of risk levels as obtained after analyzing
the posture.

Table 3.1 RULA score for height checking

RULA Level 0 1 2 3

RULA Score 1-2 3-4 5-6 7+

Risk Level Negligible Low Medium High

Investigate Investigate further Investigate and

Reqd. Action Acceptable
further and change soon change immediately

Percentage of …. ….. 100 ….

workers

22
 The table shows that current position of the height gauge is not comfortable for all
the workers and investigation and modification is required. During the personal interview of
the operators they also said that most of them is not satisfied with current condition.

Figure 3.1 Table and height gauge. Figure 3.2 Height measuring.

2. Manual transfer of parts

The second issue found is that product is transferred manually. Product is carried in specially
designed craton which carries 15 pieces in one. There are three different categories of
products which are classified according to the size of the product, which are 2k, 4k and 6k.
For the 2k parts (which are the smallest one) each batch (products in one craton) weighs 18
kg, 4k weighs 41 kg and 6k weighs 48 kg. Transferring these much weight manually will
result serious health issues

In order to get a clear data about the severity of this issue RULA assessment has been
conducted and table 2 presents the results obtained after analyzing the posture.

Table 3.2 RULA score for manual part transfer

RULA Level 0 1 2 3

RULA Score 1-2 3-4 5-6 7+

Risk Level Negligible Low Medium High

23
 Investigate Investigate further Investigate and
Reqd. Action Acceptable
further and change soon change immediately

Percentage of …. ….. …. 100

workers

3. Manual chip removal

Out of eight machines operating, only three machines have chip conveyor. Here the operator
has to remove the burr by hand and during this operation the machine has to be kept in off
condition. So here both production loss and health problems are experienced. The method
or posture of the burr removal process is very awkward and the chance of back and leg pain
is high.
RULA survey has been conducted on this work practice and posture and table 3
presents the results obtained after analyzing the posture.

Table 3.3 RULA score for manual chip removal

RULA Level 0 1 2 3

RULA Score 1-2 3-4 5-6 7+

Risk Level Negligible Low Medium High

Investigate Investigate further Investigate and

Reqd. Action Acceptable
further and change soon change immediately

Percentage of …. ….. …. 100

workers

4. Oiling of finished parts

Rust oiling mechanism used is not hygienic and efficient. The same product craton is used
for oiling purpose also and because of this it is not possible to fully immerse the part into the
oil and during the process oil is soaked in the hands.

24
 Figure 3.3 Oiling tray.

5. Arrangement of gauges
The fifth issue found out is that there is no any proper arrangement for the gauges and
equipment. The gauges are placed at the table without any order and chance of damage is
high. A proper stand should be provided to place the snap gauges.

25
 CHAPTER 4

DISCUSSIONS

The study shows that the operators lack knowledge about ergonomics and consequence of manual
material handling. The various issues found out have serious impact on the health factors and
overall productivity of the operators. So proper analysis of the problem and corresponding
modifications has to be implemented to improve the efficiency and working condition of the
operators.
So each problems has been separately considered and analyzed. According to the study
proper modification are made

4.1 HEIGHT GAUGE POSITIONING

In order to determine the optimum height of the gauge stand, anthropometric data of the current
location is collected. From the corresponding governmental organization it is obtained as 165cm.
According to this value the position of the height gauge is redesigned in such a way that the gauge
dial will come within 30° visual angle, which is the best visual angle for accurate measurements.

Figure 4.1 Current table specifications Figure 4.2 View in current table

26
 In the initial condition the angle of view was greater than 60°, which is inconvinient for
taking accurate meaasurements. Then modification is made on the table acoording to the
anthropometric values to optimise the angle of view within 30° and minimum viewing distance.

Figure 4.3 Modified table specifications Figure 4.4 View in modified table

Figure 4.5 Modified table. Figure 4.6 Height checking

In modified table.

From the figure itself we can understand that new position of the height gauge is very
convenient for the operator. After completing the modification RULA survey has been conducted

27
for the new height checking posture, table 4 presents the results obtained after analyzing the
posture.
Table 4.1 RULA score for height checking in modified table
RULA Level 0 1 2 3

RULA Score 1-2 3-4 5-6 7+

Risk Level Negligible Low Medium High

Investigate Investigate further Investigate and

Reqd. Action Acceptable
further and change soon change immediately

Percentage of 66 33 …. ….
workers

From the RULA score it is understood that the new modification is best suited for operator
conditions and the posture of height checking is comfortable.

4.2 MANUAL CHIP REMOVAL

Considering the eight CNC machines only three machines have chip conveyors, and for the five
machines conveyor is damaged or under maintenance. So for these five machines the operator has
to remove the chip manually. Frequency of chip removal vary according to the number of parts
machined or the material removal rate. In certain machines when the machine is running chip get
tangled on the turret which will result in line mark on the part surface and abnormal sound from
the machine. As a result the operator has to stop the operation in order to remove the chip and
restart the operation again. When chip excessively accumulates in the machine cabin the operator
has to stop the machine in order to remove the chip.
In order to evaluate the effect of this inconvenient work practice on the production
efficiency a study has been conducted about the loss of time due to manual chip removal. Data has
been taken for one week duration for the first shift operation and from this value average loss time
has been found out. It is found out as;

28
 Table 4.2 Average time loss due to manual chip removal

Machine Average loss time (minutes)

Machine 1 15

Machine 2 10

Machine 3 15

Machine 4 15

10
Machine 5

This value is only for the first shift, for one day loss time this value should be multiplied
with three. By comparing this value with the individual machine efficiency value taken by the
company it is found out that for these five machines there is about 20% reduction in efficiency.
To check the health problem associated with manual chip removal RULA (Rapid upper
limp assessment) survey has been conducted. RULA score for manual burr removal process is
obtained as 7 and it indicate high level of risk which shows that this work practice needs further
investigation and proper changes should be carried out immediately. Re - establishing the chip
conveyor is the best solution available for this issue so suggestion has given to the management to
re-establish the conveyor system for the machine and they have re- established it.
After re – establishing the conveyor individual machine efficiency of consecutive months
has been compared to find the effect of conveyor in production. For all five machine conveyors
has been repaired and re – established by January last. Efficiency values of December, January
and February has been taken, table 5 presents the values of individual machine efficiency,

Table 4.3 Monthly production efficiency

Overall production efficiency
Machine
December January February

Machine 1 54.41 60.92 70.15

29
 Machine 2 54.35 56.36 68.36

Machine 3 60.82 61.23 71.54

Machine 4 47.49 40.98 62.55

57.9 57.38 69.56

Machine 5

4.3 MANUAL TRANSFER OF PARTS

To conduct the ergonomic survey of manual material transfer, weight of the parts during every
machining stage has been found out. There are three different categories of products are in there;
2k, 4k and 6k. Product movement is done in three stages; initial raw material collection from
forging department, transfer after machining -1 and transfer after machining-2. Products are moved
in a craton which Carries 15 pieces at a time. In each stage operator has to carry 15 pieces and the
total weight includes weight of 15 pieces and the weight of craton. Weight of batch of products in
each stage is obtained as;
Table 4.4 Weight of a batch of products

Weight of a batch including craton (kg)

Stage of operation
2k 4k 6k

Raw material from forging 17.8 41.5 47.8

After machining - 1 15.7 29.5 40.4

After machining - 2 11.95 20.5 30.4

From analyzing this data itself we can understand that transferring this much weight
manually will result in serious health problems, doing this kind of work regularly will result in
permanent damage of muscles and joints.

30
 In order to check the severity of health issues associated with the manual material transfer
RULA survey has been conducted. RULA score for manual material handling is obtained as 7 and
it also shows that this work practice is injurious to the health of the operators and there is severe
chance for the occurrence of back pain and leg pain. As result the no of absenteeism will be
increased and operator morale will be reduced.

According to the RULA score this issue needs further investigation and immediate
changes. After further investigation and discussion with the management decision has been taken
to provide a trolley for material transfer. According to the decision a trolley has been designed and
fabricated for the material transferring purpose.

Trolley is designed in such a way that it is easily accessible within the plant and can be
moved through all positons of the plant. While designing the trolley dimensions are taken in such
a way that carton for all category can be easily stacked and easily accessible. In this design carton
can be accessed from all directions and they have more stability while moving.

Figure 4.7 Trolley for material transfer

31
 Figure 4.8 Trolley specifications
4.4 OILING OF FINISHED PARTS
After each stage of machining the parts has to be dipped in rust oil to avoid rust formation which
will result in rejection of the part. The oiling method currently using is not an efficient and hygienic
one. Now oiling is done by directly dipping the part into the carton in which the oil is kept. Carton
which is used for transferring the parts are used for oiling purpose also. The separating walls inside
the carton makes it difficult to fully dip the part into the oil.
During the oiling process hands of the operators is also immersed into the oil and the cotton
gloves will get soaked in oil. This results in irritation to the skin and problem while having food.
It shows that the oiling method currently using is not hygienic and efficient oiling method has to
be designed.
The main conditions which has to be satisfied while designing a oiling mechanism was;
the part has to be placed horizontally and it should be fully immersed, also oil should not get
soaked on the gloves. An oiling mechanism has been designed by satisfying these condition and
the space below the height gauge stand has been effectively utilized for this mechanism.

32
 Figure 4.9 Modified oiling mechanism

This mechanism works like a siso and counter weights (sliding weight) are provided on
both sides to ensure that the part is fully immersed in the oil, because in both sides’ parts of same
weight are provided. When a new part is placed on one jaw and a slight push is given sliding
weights will move towards that side and the newly placed part will get immersed in the oil and the
opposite side will come up. Then this part can be removed and a new part can be placed on the
empty jaw and oiling can be continued. Oil tank dimensions are designed in such a way that oil
may not spilled out when part is immersed.

33
 Figure 4.10 Modified oiling mechanism specifications

4.5 ARRANGEMENT OF GAUGES

In every stage of machining snap gauges and plug gauges are used for dimension checking, also
checking has to be done for all parts machined. So the operator has to handle the gauges frequently
so the easy accessing of the gauges will help to improve the productivity.
Currently the gauges are simply placed over the table without any order and there is no any
proper position for them. Sometimes operator has to search over the table to find the correct gauges
for checking. There is three working shifts are in there and three different operators work in a

34
machine, since there is no any proper positioning is in there they place the gauges according to
their convenience. Sometimes this will result in losing or damaging the gauges.
A proper gauge stand should be provided to place the gauges so that correct order and
position can be given to the gauges which will be common for all the operators. The gauge stand
should be designed in such a way that it should be suitable for gauges of all parts.
By considering all the above conditions a gauge stand has been designed in such a way that
the gauges can be placed and removed easily. It is designed in such a way that gauges for different
part models can be placed. So that the stand can be placed permanently to a machine, it is not
required to change it when parts model change.

Figure 4.11 Gauge stand

35
 Figure 4.12 Gauge stand Specifications

All the five modifications has been established in the production line. After these
production efficiencies of consecutive months has been taken. On analyzing these values it is found
out as there is 10% increase in the production efficiency and 8% reduction in rejection. In the
initial condition rejection rate was 15% and it has been reduced to 7%. From this data it is
concluded as these modifications has improved overall efficiency of the plant.

36
4.6 MODIFIED WORK TABLE

Figure 4.13 Modified work table

37
 CHAPTER 5

CONCLUSION

Results from these project study shows that ergonomic factors have considerable influence in the
overall efficiency of the production system. Employees working ergonomically designed
workstation have more work satisfaction and better working conditions.
Evaluation of ergonomic factors in the workstation shows that they give only a moderate
consideration to the ergonomic factors. Various health issues found out from survey shows the
severity of the problems. From personal interview it is revealed that 90% of the workers suffer
from back and leg pain and all the operators who do oiling experience skin problems. As result of
all these factors overall job satisfaction was poor and employee morale was low. So the operators
doesn’t follow the correct work practices and which results in higher rejection rate (15%).
By adjusting the position of the gauge effort and time required for height checking has
reduced and chance of back pain has reduced to significant level. By providing the trolley and re-
establishing the chip conveyors the management has developed a feeling that they do care for the
health of their employees. It will help to improve the morale of the workers which will be reflected
in the overall efficiency of the production. By providing the oiling mechanism both company and
operators will get benefitted, skin problems due to oil soaking will be solved and rejection due to
rusting can be avoided. Providing a proper arrangement for the work table and gauges will help to
reduce the unnecessary motion of the operator, which will help to improve the efficiency.
It is observed that simple modifications has made better difference in the quality of work
as well as the level of satisfaction of the operators. After completing all the modifications
efficiency of the consecutive months has compared and results shows 10% improvement in overall
plant efficiency and rejection rate has reduced from 15% to 8%. From all these values and results
we can understand the importance of ergonomics in production process.

38
 REFERRENCES

[1] Jeffrey E. Fernandez and Michael Goodman Ergonomics in Workplace Exponent health
Group
[2] John R Wilson 2000 Fundamentals of ergonomics in theory and practice Applied
Ergonomics 31 557-567
[3] Baba Md Deros, Nor Kamaliana Khamis, Ahmad Rasdan Ismail, Haris Jamalddin,
Azmi Mat Adam and Sarudin Rosli 2011 An ergonomic study on assembly line
workstation design American Journal of Applied Sciences 8(11) 1195-1201
[4] Terry Bossomaier, Agostino Bruzzone, Antonio Cimino, Francesco Longo and
Giovanni Mirabelli Scientific approaches for the industrial workstations ergonomic
design: a review
[5] Martina Gasova, Martin Gasova and Andrel Stefanik 2017 Advanced industrial tools
of ergonomics based on Industry 4.0 concept 192 219-224
[6] Baba Md Deros, Dian Darina Indah Darius and Ishak Mohamed Basir 2015 A study
on ergonomics awareness among workers performing manual material handling activites
195 1666- 1673
[7] U. S. Department of labor occupational safety and health administration 2000
Ergonomics: The study of work
[8] Andrea LESKOVA 2014 Designing of manual workstation structure with emphasis on
ergonomics
[9] Ansari N A and Dr. Sheikh M J 2014 Evaluation of work posture by RULA and REBA:
A case Study 11(4) 18-23
[10] Lynn McAtamney and Nigel Corlett 1993 RULA: a survey method for the investigation
of work-related upper limb disorders 24(2) 91-99
[11] Ergonomics plus A step-by-step guide Rapid Upper Limb Assessment (RULA)

39
 LIST OF PUBLICATIONS

1. J.Babu , Ajith James , Jose Philip and Shankar Charaborty, Application of the grey-based
fuzzy logic approach for materials selection" has sent for consideration for publication in
International Journal of Materials Research, Hanser Publishers, Germany (IF-0.681) DOI
10.3139/146.111538. 108 (9) 2017 pp 702-709

2. J. Babu, Jose Philip, Varckychen, Ajith James “Optimisation of forming depth and
pressure of box shaped Superplastic forming using Desirability function” in SJCET
Journal of Engineering and Management. July-December 2016, pp 32-37
3. J. Babu, Ajith James, Varchy chen, “Optimisation and selection of forming depth and
pressure of box shaped Superplastic forming using grey based fuzzy logic” accepted for
presentation at Marri Laxman Reddy Institute of Technology and Management, Hyderabad
, Telangana. Proceedings will be published Material Science and Engineering -IOP
Science- ISSN: 1757-8981

4. J.Babu , Ajith James , Shankar Charaborty and J.P.Davim. “Application of the Mutivariate
loss function and Distance functionfor materials selection" has sent for consideration for
publication in Journal Mechanical Science & Technology- Springer Publications- (IF-
1.128) under review
5. Ajith James, Tom Zacharia. “Ergonomic Optimization of Machining Operations of Power
Transmission Shafts” has presented at the International conference RAERSST18

40