Implement the designed ergonomic work facilities

Oct 13, 2025 by vinooalluri.com 133 views

Ergonomic Work Facility Design Using the Quality Function Deployment (QFD) Method on UD. M. Irfan Shoes

Introduction

In today's fast-paced industrial world, the importance of ergonomic work facilities cannot be overstated. A well-designed work facility not only improves the productivity and comfort of workers but also reduces the risk of injury and musculoskeletal complaints. However, many small industries, including shoe manufacturers like UD. M. Irfan Shoes, often struggle to provide adequate work facilities due to limited resources and inadequate knowledge of ergonomic design principles. This article discusses the application of the Quality Function Deployment (QFD) method in designing ergonomic work facilities for UD. M. Irfan Shoes, with a focus on improving the assembly process and reducing the risk of injury to operators.

The Problem of Inadequate Work Facilities

UD. M. Irfan Shoes, like many small industries, faces several challenges in its production process. One of the major issues is the lack of adequate work facilities, which can be seen in the absence of a workpiece holder during the assembly process between the upper shoe section and the shoe reference. As a result, operators are forced to clamp the workpiece using their thighs, leading to musculoskeletal complaints and discomfort. Furthermore, the work chair used by operators is not ergonomic, made of cans and pillows as a sitting base, which does not match the dimensions of the operator's body. The layout of the components is also less organized, resulting in an unproductive work attitude and musculoskeletal complaints in the operator.

The Importance of Ergonomic Work Facilities

Ergonomic work facilities are essential for improving the productivity and comfort of workers. A well-designed work facility can reduce the risk of injury and musculoskeletal complaints, improve worker morale, and increase productivity. In the context of UD. M. Irfan Shoes, the improvement of work facilities is a must to overcome the problems faced by operators. The study aims to design an ergonomic workpiece clamp and work chair using the Quality Function Deployment (QFD) method.

The Quality Function Deployment (QFD) Method

The QFD method is a powerful tool for transforming the desires and needs of customers or operators into technical specifications that can be implemented in the design of work facilities. This method helps to identify the key factors that affect the quality of work facilities and prioritize them based on their importance. The QFD method involves several steps, including:

Customer Requirements: Identifying the desires and needs of operators, including their preferences and requirements for work facilities.
Technical Requirements: Translating customer requirements into technical specifications that can be implemented in the design of work facilities.
Design: Designing the work facilities based on the technical specifications.
Verification: Verifying the design of work facilities to ensure that they meet the technical specifications.

Data Processing and Analysis

The study begins with data processing from the Standard Nordic Questionnaire (SNQ), which identifies musculoskeletal complaints in various parts of the operator's body. The results of work posture analysis through the Rapid Upper Limb Assessment (RULA) show that there are many elements of movement in work postures that are not in accordance with ergonomic principles. The data processing and analysis help to identify the key factors that affect the quality of work facilities and prioritize them based on their importance.

Designing Ergonomic Work Facilities

The study designs an ergonomic workpiece clamp and work chair using the QFD method. The design is based on anthropometric data and operator preferences, which are obtained through the QFD method. The designed improvement includes a workpiece holder that can be easily adjusted to fit the dimensions of the operator's body, and a work chair that is designed to provide optimal support and comfort for the operator.

Results and Discussion

The results of the study show that the designed ergonomic work facilities can improve the productivity and comfort of operators. The time needed to complete the assembly process with the new work facility is identified to be 228 seconds, which means there is a reduction in time of 87 seconds or a decrease of 28.61%. The results also show that the designed ergonomic work facilities can reduce the risk of injury and musculoskeletal complaints in operators.

Conclusion

The application of the QFD method in designing ergonomic work facilities for UD. M. Irfan Shoes is an important step to improve the welfare of the workforce and the quality of production. The study demonstrates the effectiveness of the QFD method in transforming customer requirements into technical specifications that can be implemented in the design of work facilities. The results of the study show that the designed ergonomic work facilities can improve the productivity and comfort of operators, reduce the risk of injury and musculoskeletal complaints, and increase the quality of production.

Recommendations

Based on the results of the study, the following recommendations are made:

Implement the designed ergonomic work facilities: The designed ergonomic work facilities should be implemented in the production process to improve the productivity and comfort of operators.
Continuously monitor and evaluate the work facilities: The work facilities should be continuously monitored and evaluated to ensure that they meet the technical specifications and customer requirements.
Provide training and education: Operators should be provided with training and education on the use and maintenance of the designed ergonomic work facilities.
Invest in better work facilities: Small industries like UD. M. Irfan Shoes should invest in better work facilities to improve the welfare of the workforce and the quality of production.

Future Research Directions

The study provides several future research directions, including:

Further improvement of the QFD method: The QFD method can be further improved by incorporating new techniques and tools, such as artificial intelligence and machine learning.
Application of the QFD method in other industries: The QFD method can be applied in other industries, such as manufacturing, healthcare, and education, to improve the quality of work facilities and reduce the risk of injury and musculoskeletal complaints.
Development of new ergonomic work facilities: New ergonomic work facilities can be developed using the QFD method to improve the productivity and comfort of operators.
Q&A: Ergonomic Work Facility Design Using the Quality Function Deployment (QFD) Method

Introduction

In our previous article, we discussed the importance of ergonomic work facilities and the application of the Quality Function Deployment (QFD) method in designing ergonomic work facilities for UD. M. Irfan Shoes. In this article, we will answer some frequently asked questions (FAQs) related to ergonomic work facility design using the QFD method.

Q: What is the Quality Function Deployment (QFD) method?

A: The QFD method is a powerful tool for transforming customer requirements into technical specifications that can be implemented in the design of work facilities. It involves several steps, including customer requirements, technical requirements, design, and verification.

Q: What are the benefits of using the QFD method in ergonomic work facility design?

A: The QFD method provides several benefits in ergonomic work facility design, including:

Improved productivity and comfort of operators
Reduced risk of injury and musculoskeletal complaints
Increased quality of production
Improved worker morale and satisfaction
Reduced costs associated with worker compensation and training

Q: How does the QFD method help in designing ergonomic work facilities?

A: The QFD method helps in designing ergonomic work facilities by:

Identifying customer requirements and priorities
Translating customer requirements into technical specifications
Designing work facilities that meet the technical specifications
Verifying the design of work facilities to ensure that they meet the technical specifications

Q: What are the key factors that affect the quality of work facilities?

A: The key factors that affect the quality of work facilities include:

Operator preferences and requirements
Work process and tasks
Equipment and tools used
Work environment and layout
Safety and health considerations

Q: How can the QFD method be applied in other industries?

A: The QFD method can be applied in other industries, such as manufacturing, healthcare, and education, to improve the quality of work facilities and reduce the risk of injury and musculoskeletal complaints.

Q: What are the limitations of the QFD method?

A: The QFD method has several limitations, including:

Complexity of the method
Time-consuming and resource-intensive
Requires expertise and training
May not be suitable for all types of work facilities

Q: How can the QFD method be improved?

A: The QFD method can be improved by:

Incorporating new techniques and tools, such as artificial intelligence and machine learning
Developing new methods and tools for data collection and analysis
Improving the user interface and user experience
Providing training and education for users

Q: What are the future research directions for the QFD method?

A: The future research directions for the QFD method include:

Further improvement of the QFD method
Application of the QFD method in other industries
Development of new ergonomic work facilities using the QFD method
Investigation of the effectiveness of the QFD method in improving worker productivity and comfort

Conclusion

In conclusion, the QFD method is a powerful tool for designing ergonomic work facilities that meet the needs and preferences of operators. By understanding the benefits, limitations, and future research directions of the QFD method, designers and manufacturers can improve the quality of work facilities and reduce the risk of injury and musculoskeletal complaints.