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Analysis and optimisation of injection moulding work cell: an ergonomic study
2000 (English)Independent thesis Advanced level (professional degree), 20 credits / 30 HE creditsStudent thesis
Abstract [en]

The objective of this project is to improve the productivity and the Occupational Health and Safety factor of a manufacturing cell at Quality Plastics Pty. Ltd., which produces plastic injection moulded handles. The project involves the investigation into the areas of workspace design, layout and material handling system design, and organisational changes. The work cell, investigated in this project, consists of two workstations: production and quality inspection and testing. Its operators have a limited set of work tasks where the same elements are repeated with only short intervals between them. When performing the work, the operators' postures put large loads upon their upper limbs as well as greatly increase their risk of RSI (Repetitive Strain Injuries). Also, due to the fact that there are several in-process storage areas it has been determined that the current material handling is both straining and time-consuming for the operators. Finally, the performed time study showed that the operator utilisation at the production station is not optimal due to approximately nine seconds of waiting time every work cycle. In order to give the operators motivational and informational feedback, Quality Plastics Pty Ltd. should introduce weekly meetings, expand the operators job content and introduce a multi-factor wage incentive plan. To ease the production and improve the work postures at the production station, a new rail system combined with an adjustable platform should be installed. This solution eliminates some critical movements and is designed to fit a range of users from the 5th %ile woman to the 95th %ile man. Thirdly, by letting the operator at the production station perform the testing, the outcome per labour hour could be improved by 37 %. A new work cell layout would also decrease the material handling and the number of in process storage areas. Finally, to improve the quality of the handles, a new jig with sensors should be designed. This would lower the probability of misplacing the ropes and decrease the number of rejections.

Place, publisher, year, edition, pages
Keyword [en]
Technology, Arbetsplatsutformning, Ergonomi, Antropometri, Human factors, Produktionsteknik, RULA, Tidsstudier
Keyword [sv]
URN: urn:nbn:se:ltu:diva-51505ISRN: LTU-EX--00/341--SELocal ID: 8b641e5f-ef56-4b04-b3f9-45d3de8263aeOAI: diva2:1024867
Subject / course
Student thesis, at least 30 credits
Educational program
Industrial Engineering and Ergonomics, master's level
Validerat; 20101217 (root)Available from: 2016-10-04 Created: 2016-10-04Bibliographically approved

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