TABLE OF CONTENT
Abstrak i
Abstract ii
Dedication iii
Acknowledgement iv
Table of Content v
List of Tables viii
List of Figures x
List Abbreviations, Symbols and Nomenclatures xi
CHAPTER 1: INTRODUCTION 1
1.1 Background Study
1 1.2
Problem Statement 2
1.3 Objective of Study
4 1.4
Scope and Limitation of Study 5
1.5 Report Outline
6
CHAPTER 2 : LITERATURE REVIEW 8
2.1 Ergonomics Features Requirement of the CNC Lathe Machine
8 2.1.1 Workstation Design of CNC Lathe Machine
8 2.1.2 Ergonomics Features in CNC Lathe Machine
10 2.1.3 Methods to Determine the Ergonomics Features
11 2.1.4 Survey by using Questionnaire
12 2.2
Redesigning the CNC Lathe Machine 13
2.2.1 Administrative Control and Engineering Control 13
2.2.2 Pilot Study 14
2.2.3 Quality Function Development QFD 14
2.2.4 Kano Model 17
2.2.5 Morphological Chart 20
v
2.3 Validation of Working Posture CNC Lathe Machine
21 2.3.1 CATIA Software
21 2.3.2 RULA analysis
24 2.4
Difference between Previous Studies and the Current Study 27
CHAPTER 3: METHODOLOGY 30
3.1 Ergonomics Features Requirement in CNC Lathe Machine
30 3.1.1 Questionnaire Development
30 3.1.2 Pilot Study
30 3.1.3 Alpha Cronbach
30 3.1.4 Respondents
33 3.1.5 Survey Period
33 3.1.6 Survey Method
34 3.2
Redesign the CNC Lathe Machine 34
3.2.1 Kano Model Analysis 34
3.2.2 House of Quality HoQ 37
3.2.3 Sketching
42 3.2.4
Morphological Chart 44
3.2.5 Scoring and Screening
45 3.2.6
CADCATIA Software 42
3.3 Validation of working posture at CNC Lathe Machine
47 3.3.1
Manikin development in body posture analysis 47
3.3.2 RULA analysis by using CATIA Software
50
CHAPTER 4: RESULT AND DISCUSSION
4.1 Ergonomics Features Required by the Machinist to Improve
54
the Workstation Design of CNC Lathe Machine 4.1.1 Background Information
54 4.1.2 Difficulties Experienced in Handling the
56
vi
4.1.3 Parts of the bodies that experienced physical fatigue 59
by the machinists 4.1.4
Ergonomics Features Requirements 4.2
Redesign the existing CNC lathe machine 65
4.2.1 Kano Method Analysis 65
4.2.2 House of Quality HoQ
67 4.2.3
Morphological Chart 72
4.2.4 Final design 77
4.3 Validation of working postures analysis at existing
80 CNC lathe machine
4.3.1 Working postures analysis at the existing CNC lathe machine 80
4.3.1.1 Working posture while lifting the work piece 80
4.3.1.2 Working postures while hold the workpiece 83
4.3.1.3 Working posture while loading a workpiece 85
4.3.1.4 Working posture while changing the tool bit 86
4.3.1.5 Working Posture while Installing the Program 89
4.3.1.6 Working postures analysis at the redesigned 91
CNC lathe machine workstation
CHAPTER 5: CONCLUSION AND FUTURE WORK 100
