International Journal of Innovative Research and Development

Abstract

The significance of this study is to identify the burden points in the machining line to ensure a healthy and safe working environment. Industrial fatigue can cause occupational injuries and musculoskeletal disorders in the long run. This can also lead to the decrease in the productivity and increase in absenteeism. To identify the burden points; method study, time & motion study and video ethnography should be performed. Based on the Standardized Ergonomics Study Chart, the burden points in the line need to be evaluated on all work elements in the work station. The evaluated burden points in some cells may be beyond the acceptable value, such elements need to be recognized and recommended for Kaizen. With the increasing customer demand it is very important to set up a correct ergonomically designed work place in the industries as the worker performs repetitive jobs for 8hrs in a day. Fatigue not only leads to injury but also to incorrect working postures. So these incorrect postures needs to be identified and the burden points should be rectified.  The main emphasis of this study is to reduce the burden and to improve the feasibility of working conditions.

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Abstract

In recent days, there is a huge competition between all the automobile industries, Supplying higher quality cars at more competitive price to much more people timely is big challenge for all the automobile industries. The study is carried out based on observations made at shop floor (Genba) of manufacturing department in a leading automotive manufacturing company. Due to percentage increase in the demand of output shaft (short/long) by 20% within a month, the company was not able to cop-up with the demand by the customer due to 3M concerns. The basic waste (MUDA) at workplace means any factor that does not contribute to the manufacturing process but only raise costs, the fluctuation (MURA) refers to the irregularities and fluctuations that happen temporarily in a production schedule and in the volume of parts and the overburden (MURI) means giving too heavy mental or physical burden to workers on production sites, for Machinery it also means giving excess workloads to equipment more than it is normally capable of. Thus the main emphasis of the study is on identifying and eliminating 3M’s by performing time study, method study, motion study (Video Ethnography) to ensure safety, quality, productivity, cost, and HRD level up as well. Moreover, ergonomics study to reduce the fatigue at the machining line to improve workability, ultimately achieving customer delight by supplying 100% quality products. 

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