Ergonomi3(2),96–107,2020e-ISSN:2651-4877

Ergonomics3(2),96–107,2020DOI:10.33439/ergonomi.743276

96

THEERGONOMICRISKANALYSISWITHREBAMETHODINPRODUCTIONLINE

EminTARAKÇI1*,EmineCAN2,AhmetE.SAKALLI3,GökmenTAK4

1YükselProjeI.C,ORCIDNo:http://orcid.org/0000-0002-0926-31522İstanbulMedeniyetÜniversitesi,MühendislikveDoğaBilimleriFakültesi,İşSağlığıveGüvenliğiABD

ORCIDNo:http://orcid.org/0000-0003-1192-29943İstanbulAydınÜniversitesi,MülkiyetKorumaveGüvenlik,İşSağlığıveGüvenliğiProgramı

ORCIDNo:http://orcid.org/0000-0003-0445-07224EyüpsultanMah.MezarlıkYoluORCIDNo:http://orcid.org/0000-0001-7168-7573

Keywords AbstractErgonomicriskanalysisREBAAssemblyworkMusculoskeletaldiseasesWork-relateddiseases

Ergonomics isagroupofmultidisciplinarystudiesthat investigateandimprovethecompatibility of humanswith themachine and the environment by examining thephysical, environmental and psychological risk factors. The primary purpose ofergonomicsistoensureemployeehealthandsafety,andincreaseworkefficiency(suchas reduced idle capacity, increasedproduction, increasedproductquality).Becauseemploying workers in a healthy and safe condition enables an increase in workefficiency.Inthisstudy,ergonomicriskanalysiswasselectedontheproductionlineofanenterprisewiththeREBAmethodandsuggestionsforimprovementwereincluded.Theworkingclusterconsistsof30unskilledworkersontheproductionline.Asaresultoftheanalysis,66.6%oftheproductionprocessisatmediumriskand33.4%isathighrisk.Aftertheimprovementworkstobedone,itisexpectedthatergonomicriskswouldreduceandanincreaseinproductionandefficiency.

ÜRETİMHATTINDAREBAYÖNTEMİİLEERGONOMİKRİSKANALİZİ

AnahtarKelimeler ÖzErgonomikriskanaliziREBAMontajçalışmasıKas-iskelethastalıklarıİşleilgilihastalıklar

Ergonomi, fiziksel, çevresel ve psikolojik risk faktörlerini inceleyerek insanlarınmakine ve çevre ile uyumluluğunu araştıran ve geliştiren çok disiplinli çalışmagrubudur.Ergonominintemelamacı,çalışanlarınsağlığınıvegüvenliğinisağlamakveiş verimliliğini arttırmaktır (atıl kapasitede düşüş, üretimde artış, ürün kalitesindeartışgibi).Çünkü;çalışanlarısağlıklıvegüvenlibirşekildeçalıştırmakişverimliliğindeartış sağlar.Buçalışmada,bir işletmenin seçilenüretimhattındaREBAyöntemi ileergonomik risk analizi yapılmıştır ve iyileştirme önerileri sunulmuştur. Çalışmakümesiniüretimhattındaçalışan30düzişçioluşturmaktadır.YapılanREBAanalizisonucunda, üretim sürecinin %66,6'sı orta riskte ve %33,4'ü yüksek risk altındaolduğugözlenmiştir.Yapılacakiyileştirmeçalışmalarısonucundaergonomikrisklerinazalacağı,üretimveverimlilikteartışolmasıbeklenmektedir.

AraştırmaMakalesiBaşvuruTarihiKabulTarihi

:27.05.2020:15.07.2020

ResearchArticleSubmissionDateAcceptedDate

:27.05.2020:15.07.2020

*Sorumluyazare-posta:tarmuhendislik@gmail.com

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1.Introduction

With the development of technology, althoughautomationsystemshavebeenusedinsteadofahuman in industry, human labor is stillindispensableinmanyproductionsystems.Whenergonomic risk factors are examined in thesesystems where manpower is needed, workingpositions, especiallyphysical risk factors, areofgreat importance. One of the productionprocesses that need manpower is assemblyprocesses. In some work done in assemblyprocessesinorganizations,posturesthatdisturbemployees emerge. The employees in theassembly process work by leaning, rotating,standingorlyingdown.Thesestudiesemployeehealth and performance affect and areergonomicallyunsuitablewaysofworking.

Improperposturesaredefinedasthedeviationofone or more limbs from the stationary bodyposture. Incorrect working postures ofemployees can cause pain and discomfort andfatigueinsomebodyareas,especiallyintheback,waist and neck. For this reason, these posturesnotonlycausemusculoskeletaldisordersbutalsodecrease theworkperformanceandproductionquality of the employee. Examining andevaluating the working postures, which is animportantissueforboththeorganizationandtheemployee,hasanimportantplaceinthescienceofergonomics(Akayetal.,2003).

According to a manual worker, the height of awork surface is an essential determinant of theupper limb (arms) effort and the potential forinjury to the musculoskeletal system. Theindustrial ergonomicdesign suggestsaworkingheightofabout5cmbelowtheelbowheightandis an acceptable range 12.5 cm below, 2.5 cmabovetheelbowheight(Berqueretal.,2002).

Two-thirdsofworkersinEuropestatethattheyperformrepetitivemovementsofthehandorarmforatleastaquarteroftheirworkingtime.Thiskindofrepetitivemotionexposureisassociatedwith the risk of developing musculoskeletaldisordersintheupperextremities(Claudonetal.,2020).

Work-related musculoskeletal disorders are aproblemformanycountriesintheworld.IntheUK,theHealthandSafetyExecutive(HSE)statedthat upper extremity (arms) disorders are notonly seen in a particular business line but arecommon in jobs requiring the labor force.However, HSE reports that work-relatedmusculoskeletaldisordersarethemostcommonoccupational diseases affecting 1 millionemployees a year, with problems such as lowback pain, joint injuries and recurrent strain

injuries. In a country-wide study in Taiwan,37.0%of 18.942 people reported that they hadwork-related musculoskeletal disorders. In theUnitedStates,BureauofLaborStatisticssaidthat552,528 people had work-relatedmusculoskeletaldiseasesanda totalof329,920employees were unemployed in the servicesector in the annual survey of occupationalinjuriesandillnessesin2001(Fangetal.,2007).

Martinetall.(2009),theyanalyzedthesituationssurrounding workplace tasks performed usingauxiliary equipment (ladders, scaffolding, etc.)and that could cause falls. They identified thecauses that had the most significant impact onaccidents involving ancillary equipment. Thesereasons includetheadoptionofwrongposturesduringworkandtheinsufficientknowledgeofaworker,coveringmostof thesafetyregulations.Similarly, the duration of the tasks has beenassociated with these variables and thus, theaccidentrate.

Musculoskeletal system diseases constitute asignificantpartofdiseasesexperiencedbymostorganizations.Frombackstraintocarpaltunnelsyndrome, in an organization, musculoskeletalsystemdiseasescanfind40%ormoreof injurycases and 60% of compensation costs. Safetyexperts, engineers and human resourcesmanagers have turned to the science ofergonomics tounderstandandaddressworkingconditions that increase the risk ofmusculoskeletal diseases. Production managersalso resort to the science of ergonomics forapplications that increase efficiency andefficiency. The musculoskeletal system oftenrequires a two-way ergonomics application toprevent disease and increase efficiency: areactive program for identifying, analyzing andcorrecting "problematic jobs", a proactiveprocess that harmonizes ergonomics with theprocessandproductdesign(Adams,2005).

Anotherhealthproblemhighlighted in researchin recent years is musculoskeletal disorders orphysical symptoms. These aremuscle, nervous,orjointdisordersthatcanoccuranywhereonthebody, although they most commonly affect theneck, back, and upper extremities. Workingconditionsaredirectlyrelatedtomusculoskeletaldisorders, although these disorders can resultfromfactorsoutsidetheworkplaceandevenhavepersonal causes. Prevention of musculoskeletaldisordersisdirectlyrelatedtothecorrectdesignof the work (for example, allocated space orproviding adequate lighting) and physicaldemands(forexample,transportingheavyloadsandperformingrepetitivetasks)(García-Herreroetal.,2012).

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Inadditiontobeingaproblemofmusculoskeletalsystem disorders for workers' health, thesedisorderscreateasignificantfinancialburdenonsociety. Most of the financial losses associatedwith occupational accidents and occupationaldiseases include musculoskeletal disorders(Takala, 2002), and these musculoskeletaldisordersarethemaincauseoftime-lossinjuriesindevelopedcountries(Brageetal.,1998;Woolf&Pfleger,2003).

García-Herreroetal., (2012), reports thatwhenlooking at studies on occupational health andsafety aimed at preventing injury, there areenough studies focused on physical aspects,ergonomicfactorsandmusculoskeletaldisorders(DeJongetal.,2003;Ghahramani,2000;Ghoshetal., 2010; Hess et al., 2004) Also, hygienicconditions such as temperature and noise arefocused(Anttonenetal.,2009;Ashrafetal.,2005;Morabitoetal.,2006).

Therearemanystudiesintheliteraturesuchas;ergonomicconditions(Hoyos,1995;Makhbuletal., 2008), ergonomic working conditions, jobsatisfaction (Kaya et al., 2011) focused on theimpactofmonotonousworkandrepetitivetasks(Melamedetal.,1995)onstress.

It has also been found that stress leads toincreased absenteeism rate, accidents, injuriesand diseases. Stress does not only affect thehealth of the individual, but it alsodisrupts thefunctioningoftheorganization(Sakallı,2019).

Ergonomics improves employee productivity,protects the health and ensures safety. Besides,ergonomic working conditions increase jobsatisfaction. This situation directly or indirectlyaffectstheproductivityoftheemployee(Kayaetal.,2011).

Human factor engineering (Ergonomics)researches information about human behavior,abilities, limitationsandothercharacteristics todesign tools, equipment, machinery, systems,work, work-flow and order, and environmentalfactorstoprovideefficient,safe,comfortableandeffectiveuseandapplies(Güler,1997:9).

Ergonomics acknowledges that any systemalways produces two results: performance andwell-being. The focus of ergonomics on twocommonresultsisafeaturethatdistinguishesitfromotherdisciplines.Otherdisciplinessuchasengineering, psychology, andmedicine focusononeoftheresultswithergonomics,butnotbothresults(Duletal.,2012).

According to García-Herrero et al.'s study in2012, optimizing these conditions related to

hygiene and ergonomics in the workplace canreducetheoccupationalaccidentrateuptofourtimestheinitialvalueaccordingtothesensitivityanalysisperformed.

Another factor that makes working stanceimportant isthedecreaseinthelevelofquality.AccordingtothestudydonebyAxelssonin1995,thepoorqualityoftheworkinthewrongposturestatedthat itwas10timesmorethandoingthesamejobintherightposture.Becausethereisasignificant difference between a job that theemployeewill dowithout being forced and thequality level of the job when they are forced(Axelsson,1995).

In this study; The postures during the work,especially the working ailments caused byimproper working postures on the productionlines, and workforce losses were examined.ErgonomicriskanalysiswasperformedwiththeREBA (Rapid Entire Body Assessment) methodby observing the 6 stages ofworkstations/production line determined toimprovetheimproperworkingpostures.

Relatedimprovementsuggestionsarepresentedaccordingtotheriskscoresobtained.Asaresultof improvement studies, it is aimed to protectemployeehealthandincreaseworkefficiencybyreducingthedisturbancesinthemusculoskeletalsystem.

2.ApplicationPlaceandMethod

2.1.ApplicationPlace

This study was carried out in a facility thatproduces water and gas valves of variousdiameters. Products are intended to use forresidentialandindustrial.Valvesproducedintheheavymetalindustryenvironmentconsistoffourmain parts: trunk, ball, gasket and open/closeboom.

In this study, it was aimed to determine theergonomically inappropriate working posturesandmovements by observing the stages of thevalve production process. Ergonomic riskanalysis was carried outwith the REBA (RapidEntire Body Assessment) method by observingand recording 6 stages of production lineemployees to determine and improve theinappropriateworkingposturesatthediecastingindustryfactory.Thereare30employeesinthe6stagesoftheproductionline.Allofthemhaveaminimumof5yearsofexperienceand theyareunskilledworkers.Thestudyclusterwaschosenrandomly.

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Failureergonomicposturesandmovementshavebeendetectedandanalyzed.

2.2. Method (REBA- Rapid Entire BodyAssessment)

The REBA (Rapid Entire Body Assessment)methodisanobservationalmethoddevelopedtoanalyzeallpartsofthebodyandtoidentifyrisksin body positions (Hignett and McAtamney,

2000). Thismethod enables the detection andprevention of inappropriate working posturesthatmaycausework-relatedmuscleandskeletaldisorders.

WhencalculatingtheREBAscore,bodyparts;ItisdividedintotwogroupsasGroupA(Body,Neck,Legs) as seen in Figure 1 and Group B (UpperArms,LowerArms,Ankles)asseeninFigure2.

Figure1.GroupABodyPartDiagramandScores

Figure2.GroupBBodyPartDiagramandScores

A score consisting of a combination of thesescoresisdeterminedwiththehelpofTable1bydeterminingthescoresofthetrunk,neckandlegsseparately.

A Score is obtainedby adding theLoad/Forcescoretothisscore.

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Table1.TableAandLoad

B score consisting of a combination of thesescoresisdeterminedwiththehelpofTable2bydeterminingthescoresofupperarm,lowerarmandwristsseparately.

BScoreisobtainedbyaddingaCouplingscoretothisscore.

Table2.TableBandCoupling

Then, using Table 3, C Score, which is acombinationofAandBscores,isobtained.

REBA Score is obtained by adding the ActivityscoretotheCScore.

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Table3.TableCandActivityScore

Figure3.REBAScoreSheet

Table4.REBAActionLevels

The REBA (Rapid Entire Body Assessment)methodisanobservationalmethoddevelopedtoanalyzeallpartsofthebodyandtoidentifyrisksinbodypositionsinFigure3,Table4.

Action is taken improvement activity accordingtothedegreeofriskdetected.

3.ResultsofApplication

In this study, it was aimed to determine theergonomically inappropriate working posturesandmovements by observing the stages of thevalve production process. Failure ergonomicposturesandmovementshavebeendetectedandanalyzed.

As a result of the analysis, as seen in Table 5,66.6% of the production process is at mediumrisk and 33.4% is at high risk. After theimprovementworkstobedone,itisexpectedto

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increaseemployeesatisfactionandperformance,production efficiency, quality and productionspeedon theotherhanddecreasework-relateddiseasesthatmayoccurintheemployee.

3.1.CuttingtheBrassRodBalewithShears

The employee has to stoop the waist and neckforwardandapplyastrongforcetotheshearstocut the bale tie. As seen in Figure 4, the REBAscoreis6andtherisklevelismedium.

Improvementactivityisnecessary.

Figure4.CuttingtheBrassRodBalewithShearsandREBAScore

3.2.LoadingtheRawValvesonTheDeburringMachine

Sliced bar pieces from the sawing machine arepressed in the press machine and after beingshaped as a valve, they are loaded to thedeburringmachinebyaworkerusingashovel.As

seen in Figure 5, when the REBA analysisperformedinthisstage,theREBAscoreis10,andtherisklevelishigh.

Improvement activity is necessary as soon aspossible.

Figure5.LoadingtheRawValvesonTheDeburringMachineandREBAScore

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3.3. Processing of The Thread Parts of TheValvesonCNC

Deburring valves are placed manually by anemployee in the CNC machine to thread their

mouth. In the REBA analysis performed in thisstage, the REBA score is 6 and the risk level ismedium(Figure6).

Improvementactivityisnecessary.

Figure6.ProcessingofTheThreadPartsofTheValvesonCNCandREBAScore

3.4.RealizationofChromePlatingProcess

The valves are immersed in the plating bath torealizechromeplating.Thisprocessiscarriedoutinthesamewayinthreedifferentbathroomsina

row. The employee always has to stoop. In theREBAanalysisperformed inFigure7, theREBAscoreis8andtherisklevelishigh.Improvementactivityisnecessaryshortly.

Figure7.RealizationofChromePlatingandREBAScore

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3.5.AssemblyofValveParts

Valve parts are automatically mounted to eachotherbymanuallyplacingthemoldsonthedrumin a machine. The employee takes the 3 mainparts(trunk,gasket,cap)withhishandfromthe

materialcaseonthesideandplacestheminthemold. In the REBA analysis performed in thisstage, the REBA score is 5 and the risk level ismedium. Improvement activity is necessary(Figure8).Improvementactivityisnecessary.

Figure8.AssemblyofValvePartsandREBAScore

3.6.PlacinginThePackagingMachine

Theassembledvalvesareplacedinthepackagingmachinemanuallybytheemployees.Asaresult

of thecalculation,asseeninFigure9, theREBAscore is 5 and the risk level is medium.Improvementactivityisnecessary.

Figure9.PlacinginThePackagingMachineandREBAScore

4.Conclusion

In conclusion, ergonomically inappropriateworking postures and movements were

determinedwiththeREBAmethodbyobserving6stagesoftheproductionline.As a result of the analysis, as seen in Table 5,66.6% of the production process is at mediumriskand33.4%isathighrisk.

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Table5.REBAScoresandRiskLevelsbefore&afterImprovementSuggestions

ProcessofProductionLine

FirstRebaScore

FirstRiskLevel

Action ImprovementSuggestions

LastRebaScore

LastRiskLevel

Cuttingthebrassrodbalewithshears 6 Medium Necessary

Usingelectronicironcuttingshears

1 NegligibleRaisingthebarfeedingplatform

Loadingtherawvalvesonthedeburringmachine

10 High NecessarySoon

Usingmobileloadplatform1 Negligible

Establishingaconveyortransfersystem

ProcessingofthethreadpartsofthevalvesonCNC

6 Medium Necessary

Placingthematerialboxestobeprocessedatanadjustableangleanddistance

2 Low

Realizationofchromeplatingprocess

8 High NecessarySoon Raisingthehangerlength 3 Low

Assemblyofvalveparts 5 Medium Necessary

Placingsemi-finishedmaterialboxesatanadjustableangleanddistance

2 Low

Placinginthepackagingmachine 5 Medium Necessary

Placingtheproductmaterialboxesatanadjustableangleanddistance

2 Low

A significant decrease in risk levels is expectedafterimprovementsuggestionsinTable5.

In consequence of improvements in the designand providing rotation between the stationsamongtheemployees;It isexpectedtoincreaseemployee satisfaction and performance,production efficiency, quality and productionspeedon theotherhanddecreasework-relateddiseasesthatmayoccurintheemployee.

Khanetall.,(2018)inhiswork,theydeterminedthattheshoulderwasthemostaffectedbodyareaandthentheneck,bycombiningREBAandNMQintheergonomicanalysisof51railwayworkers.

In a study, the prevalence of musculoskeletaldisordersfordifferentbodypartswas75.9%fortheneck,58.6%fortheshoulders,56.9%fortheupper back, 48.3% for thewaist and 44.8% forthewrist. Job analysis usingREBA showed that89.6%oflimbsingroupAand79.3%oflimbsingroupBhadascore.Onlyneckandlowbackpain

haveasignificantrelationshipwiththerisklevelsobtainedusing theREBAmethod(Rafeemaneshetall.,2013).

Similar findingswereobtainedaccording to theresults ofREBA analysis in the literature.Neck,trunkandupperarmarethemostaffectedbodyarea.

Acknowledgments

Theauthorswish to thankKayalarPresDökümLtd.forsharingtheirknowledgeandexperience.Special thanks to the editor for valuablecontributions.

ConflictofInterest

No conflict of interest was declared by theauthors.

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