Design And Ergonomics Analysis Of UTeM Bus Cockpit Arrangement.
DESIGN AND ERGONOMICS ANALYSIS OF UTeM BUS COCKPIT ARRANGEMENT
MOHD NASHROL BIN MOHD NAWI
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DESIGN AND ERGONOMICS ANALYSIS OF UTeM BUS COCKPIT ARRANGEMENT
MOHD NASHROL BIN MOHD NAWI
This report is submitted in
fulfilment of the requirements for the award of Bachelor of Mechanical Engineering (Design & Innovation)
Faculty of Mechanical Engineering Universiti Teknikal Malaysia Melaka
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SUPERVISOR DECLARATION
“I hereby declare that I have read this project and in my opinion this project is sufficient in terms of scope and quality for the award of the degree of
Bachelor of Mechanical Engineering (Design & Innovation)”
Signature:
Name: Mr Shafizal bin Mat Date: 2 July 2012
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Dedication
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DECLARATION
“I hereby declare that the work in this project is my own except for summaries and quotations which have been duly acknowledged.”
Signature:
Name: Mohd Nashrol bin Mohd Nawi Date: 2 July 2012
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ACKNOWLEDGEMENT
Greatest thanks to ALLAH S.W.T for blessing and giving me the ability to finish this project, which hopefully can contribute in further research
I would like to express my gratitude to my supervisor, Mr. Shafizal bin Mat, who guided me through the process of completing this report. He help, give advice and guidance to me how to make analysis of this project and how to prepare the report in the correct way.
A lot of thanks to all of my friends who assisting and supporting me on completing the report. They share and provide me with brilliant ideas on how to design the product and supporting me in boosting up my confidence level to finish this project.
Finally, I would like to express my thanks and love to my family that encourages and supports me in full for every trial that I have encountered. They not only helped me financially, but morally and spiritually.
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ABSTRACT
This project is about design and ergonomics analysis of UTeM bus cockpit arrangement. Ergonomics analysis will be applied within this project to investigate why UTeM bus driver having some problems when they are driving. There are some problems happen to driver bus like lower back pain, bus cockpit space area limited and etc. This study is focusing on UTeM bus cockpit arrangement and the target user is UTeM bus driver. There are some compartments included in the bus cockpit such as steering, pedal, seat, gear lever, parking brake and instrument panel. Engineering design concept was used in this project to get the information and data that related like Pugh method and House of Quality (HOQ). Five concept of conceptual design must come out before selection design done. Each concept has been designed with various designs where the position of the gear lever and parking brake is modified while the driver's seat adjusted in various ways. The best design has been selected using the Pugh method. Concept 1 was chosen as the best concept design of cockpit arrangement. The existing and new design of bus cockpit had been drawn using CATIA and ergonomics analysis is applied to get ergonomics result from the design. Comparison is made on the design of new and existing to see if the new design more ergonomic or not. The final result for existing design is 5 over 8 and the comparison shows that the new design is more ergonomics compare with the existing design with overall final score of 3 over 8. The new design can be used in the future to build a real cockpit bus arrangement and it will minimize and prevent any injury to bus driver when driving.
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ABSTRAK
Projek ini adalah mengenai reka bentuk dan analisis ergonomik terhadap susunan kokpit bas UTeM. Analisis ergonomik akan digunakan dalam projek ini untuk mengenalpasti masalah yang dihadapi oleh pemandu bas UTeM apabila mereka memandu. Terdapat beberapa masalah berlaku kepada pemandu bas seperti sakit bahagian belakang badan, kawasan ruang kokpit bas terhad dan sebagainya. Kajian ini memberi tumpuan kepada susunan kokpit bas UTeM dan pemandu bas UTeM sebagai sasaran pengguna. Terdapat beberapa bahagian di dalam kokpit bas seperti stereng, pedal, tempat duduk, tuil gear, brek tangan dan panel instrumen. Konsep rekaan kejuruteraan telah digunakan dalam projek ini untuk mendapatkan maklumat dan data yang berkaitan seperti kaedah Pugh dan Rumah Kualiti (HOQ). Lima konsep reka bentuk mesti direka sebelum pemilihan reka bentuk dilakukan. Setiap konsep telah direkabentuk dengan pelbagai rekaan di mana kedudukan tuil gear dan brek tangan diubahsuai manakala tempat duduk pemandu dipelbagaikan dalam pelbagai cara. Reka bentuk yang terbaik akan dipilih menggunakan kaedah Pugh. Konsep 1 telah dipilih sebagai konsep reka bentuk susunan kokpit yang terbaik. Reka bentuk kokpit bas yang sedia ada dan baru akan dilukis menggunakan CATIA dan analisis ergonomik (RULA analisis) digunakan untuk mendapatkan keputusan ergonomik. Perbandingan dilakukan terhadap reka bentuk baru dan sedia ada untuk melihat sama ada reka bentuk baru lebih banyak ergonomik atau tidak. Keputusan rekabentuk asal adalah 5 daripada 8 dan perbandingan menunjukkan reka bentuk baru adalah lebih ergonomik dibandingkan dengan reka bentuk yang sedia ada dengan skor keseluruhan akhir sebanyak 3 daripada 8. . Reka bentuk baru ini boleh digunakan pada masa hadapan untuk membina susunan kokpit bas yang sebenar. Reka bentuk baru ini boleh meminimumkan dan menghalang apa-apa kecederaan kepada pemandu bas ketika memandu.
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TABLE OF CONTENT
CHAPTER TITLE PAGES
DECLARATION ii
ACKNOWLEGDEMENT iii
ABSTRACT iv
ABSTRAK v
TABLE OF CONTENT vi
LIST OF FIGURES x
LIST OF FIGURES xiii
CHAPTER 1 INTRODUCTION
1.1 Project Background 1
1.2 Problem Statement 2
1.3 Objectives 2
1.4 Scope 2
1.5 Methodology 3
1.6 Project Outline 4
1.7 Summary 9
CHAPTER 2 LITERATURE REVIEW
2.1 Introduction 10
2.2 Ergonomics 11
2.2.1 Human Factors And Ergonomics 13
2.3 Driver Distraction 14
2.4 Lower Back Pain (LBP) 15
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2.7 Posture 23
2.7.1 Postural Loading 24
2.7.2 Vision and Posture of Head and Neck 25
CHAPTER 3 METHODOLOGY
3.1 Introduction 28
3.2 Design Process 28
3.3 Analysis Method 30
CHAPTER 4 CONCEPTUAL DESIGN AND SELECTION DESIGN
4.1 Introduction 31
4.2 Existing Design 32
4.3 House of Quality (HOQ) 33
4.4 Best Concept Generated 37
4.5 Ergonomics Analysis 40
4.5.1 Concept 1 40
4.5.1.1 Driver bus sitting and hold
steering position 40
4.5.1.1 Driver bus hold gear lever 41 4.5.1.2 Driver bus pull parking brake 42
4.5.2 Concept 2 44
4.5.2.1 Driver bus sitting and hold
steering postition 44
4.5.2.2 Driver bus hold gear lever 45 4.5.2.3 Driver bus pull parking brake 46
4.5.3 Concept 3 48
4.5.3.1 Driver bus sitting and hold
steering postition 48
4.5.3.2 Driver bus hold gear lever 49 4.5.3.3 Driver bus pull parking brake 50
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steering postition 52 4.5.4.2 Driver bus hold gear lever 53 4.5.4.3 Driver bus pull parking brake 54
4.5.5 Concept 5 56
4.5.5.1 Driver bus sitting and hold
steering postition 56
4.5.5.2 Driver bus hold gear lever 57 4.5.5.3 Driver bus pull parking brake 58
4.6 Concept Evaluation 60
4.7 Selection Design 61
CHAPTER 5 RESULTS AND DISCUSSION
5.1 Introduction 64
5.2 Existing design ergonomics analysis 65 5.2.1 Sitting and hold Steering 65
5.2.2 Hold gear lever 66
5.2.3 Pull parking brake 67
5.3 New design ergonomics analysis 68 5.3.1 Sitting and hold steering 68
5.3.2 Hold Gear 69
5.3.3 Pull parking brake 70
5.4 Comparison between existing and new design 71 5.4.1 Sitting and hold steering 72
5.4.2 Hold gear lever 73
5.4.3 Pull parking brake 75
5.5 Discussion 77
CHAPTER 6 CONCLUSION AND RECOMMENDATION
6.1 Conclusion 78
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REFFERENCES 80
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LIST OF FIGURE
NO TITLE PAGES
Figure 1.1 Outline of project 5
Figure 1.2 Project Flow Chart 6
Figure 2.1 Seat mounted on a seat buck and postural angles and
design specification.(Source: Se Jin Park et al., 2000) 18 Figure 2.2 Posture when driving (Source :http://marklandclinic.com/
blog/2010/12/driving-posture-and-ergonomics) 19 Figure 2.3 Three different sitting postures
(Source: Nobuyuki Shibata & Setsuo Maeda, 2010) 20 Figure 2.4 The interior Space Envelopes
(Source: Waldemar Karwowski, 2006) 20 Figure 2.5 Raw data and Overlaid RAMSIS analysis
(Source: Thomas Seitz, 2000) 21
Figure 2.6 Posture theory diagram (Source: www.antiaginghacks.com /six-tips-for-fighting-bad-posture) 23 Figure 2.7 Postural stress at the lumbo- sacral joint in the spine.
(Source: Stephen Pheasent et al., 2006) 24 Figure 2.8 Vision zones and posture of head and neck
(Source: Stephen Pheasent, 2006) 26
Figure 4.1 Existing UTeM bus cockpit 32
Figure 4.2 Existing design (CAD view) 33
Figure 4.3 Concept 1 37
Figure 4.4 Concept 2 38
Figure 4.5 Concept 3 38
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Figure 4.8 Sitting and Hold Steering (Left) 40
Figure 4.9 Sitting and Hold Steering (right) 41
Figure 4.10 Hold gear lever (left) 41
Figure 4.11 Hold gear lever (right) 42
Figure 4.12 Pull parking brake (right) 43
Figure 4.13 Pull parking brake (left) 43
Figure 4.14 Sitting and hold steering (right) 44 Figure 4.15 Sitting and hold steering (left) 45
Figure 4.16 Hold gear lever (right) 45
Figure 4.17 Hold gear lever (left) 46
Figure 4.18 Pull parking brake (right) 47
Figure 4.19 Pull parking brake (left) 47
Figure 4.20 Sitting and hold steering (right) 48 Figure 4.21 Sitting and hold steering (left) 49
Figure 4.22 Hold gear lever (right) 49
Figure 4.23 Hold gear lever (left) 50
Figure 4.24 Pull parking brake (right) 51
Figure 4.25 Pull parking brake (left) 51
Figure 4.26 Sitting and hold steering (left) 52 Figure 4.27 Sitting and hold steering (right) 53
Figure 4.28 Hold gear lever (right) 53
Figure 4.29 Hold gear lever (left) 54
Figure 4.30 Pull parking brake (right) 55
Figure 4.31 Pull parking brake (left) 55
Figure 4.32 Sitting and hold steering (right) 56
Figure 4.33 Sitting and hold steering (left) 57
Figure 4.34 Hold gear lever (right) 57
Figure 4.35 Hold gear lever (left) 58
Figure 4.36 Pull parking brake (left) 59
Figure 4.37 Pull parking brake (right) 59
Figure 4.38 New cockpit arrangement design (CAD drawing) 63 Figure 4.39 New cockpit arrangement design (drafting) 63
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Figure 5.2 Existing design when sitting and hold steering (left) 65 Figure 5.3 Existing design when hold gear lever (right) 66 Figure 5.4 Existing design when hold gear lever (left) 66 Figure 5.5 Existing design when pull parking brake (right) 67 Figure 5.6 Existing design when pull parking brake (left) 68 Figure 5.7 New design when sitting and hold steering (left) 68 Figure 5.8 New design when sitting and hold steering (right) 69 Figure 5.9 New design when hold gear lever (left) 69 Figure 5.10 New design when hold gear lever (right) 70 Figure 5.11 New design when pull parking brake (right) 71 Figure 5.12 New design when pull parking brake (left) 72
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LIST OF TABLE
NO TITLE PAGES
Table 1.1 PSM 1 Gantt Chart 7
Table 2.2 PSM 2 Gantt Chart 8
Table 2.1 The fractions (%) of service route driving with different models of bus
(Source: Olanrewaju O. Okunribido et al., 2007) 16 Table 2.2 Values for 5th to 95th percent
(Source: Scott Openshaw et al., 2006) 22 Table 2.3 Joint comforts ranges for a seated driver (degrees)
(Source: Rabiffe, 1966) 25
Table 2.4 Percent of rear-struck drivers with pain by location of pain (Source: Janella F. Chapline et al., 2000) 27
Table 4.1 House of Quality (HOQ) 35
Table 4.2 Ergonomics result when driver sitting and hold steering 60 Table 4.3 Ergonomics result when driver hold gear lever 60 Table 4.4 Ergonomics result when driver pull parking brake 61 Table 4.5 Pugh method for comparing the concept design 62
Table 5.1 Sitting and hold steering (Right) 72
Table 5.2 Sitting and hold steering (Left) 73
Table 5.3 Hold gear lever (Right) 74
Table 5.4 Hold gear lever (Left) 74
Table 5.5 Pull parking brake (Right) 75
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CHAPTER 1
INTRODUCTION
1.0 Project Background
Ergonomics is a combination of the words ergo, a Greek word meaning "work" and nomics, meaning "study" - the study of work. An applied science that co-ordinates the design of devices, systems and physical working conditions with the capacities and requirements of the workers (N. Jaffar et al., 2011).
Nowadays, public transport is one priority to consumer to travel anywhere. Public transport forms the major use of buses, taxi, and train. This public transport designed for the transport of the general public as a public service. A significant problem in the public transport sector is driver distraction (Salmon et al., 2011). There are various methods exist for investigating distraction. However, the majority are difficult to apply within the context of naturalistic bus driving. Thus, this project is proposed to design bus cockpit using ergonomic analysis. In this project, ergonomics was applied to investigate why driver distraction when they driver. This project will be focusing on UTeM bus cockpit.
Cockpit is well known as a compartment in a small aircraft in which the pilot, crews and sometimes passanger sit. However, for bus, cockpit defined as the bus driver compartment to driving that required steering, gear lever, seat, parking brake, pedal and instrument panel that include all button of bus functions like button for
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compartments at the bus cockpit have their own functions.
1.1 Problem Statement
The driver should be patience and focus in their driving in order to avoid accident occurs. The driver will face some problems during they drive and it will affect them when they are driving. Same goes to UTeM bus driver, distraction while driving is a major problem to the bus driver.
Besides, they do not feel comfortable with the current bus driver cockpit arrangement. The bus cockpit arrangement not suitable for driver to drive in whole day to pick up student from hostel to campus. It a bit difficult for driver to touch each buttons at the bus instrument panel and it will interfere driver driving.
Driver bus also get some problem when moving around the cockpit especially for fat or big driver bus because the space aroud is too limited. These problems can cause the driver not feel comfortable when sitting and can make them lost their focus to driving. Besides that, driver bus easy to get back pain when they driving especially at the lower back and easy to feel tired.
1.2 Objectives
The main objectives of this project is to design and perform the ergonomics analysis for UTeM bus cockpit arrangement.
1.3 Scope
The scopes that want to achieved for this project to make successfull and fullfill the objectives are re-design the UTeM bus cockpit arrangement that already
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must perform the new ergonomics design analysis to make a suitable, variable condition and comfortable design for UTeM’ driver bus.
The new ergonomics design of UTeM bus cockpit must do a comparison between the existing UTeM bus cockpit design to get the result that can make UTeM bus driver comfortable and can focus without no distraction when driving and not feel so tired to drive on long journey. This ergonomics design must be evaluated by using the CATIA ergonomics analysis to get the result of the new ergonomics design.
1.4 Methodology
Many methods have been used to gain an information about the UTeM bus cockpit arrangement. The method used are doing an interview with UTeM driver bus, and doing article review about the ergonomics function of the bus cockpit arrangement.
The interview done by do talk with UTeM driver bus to know what effect while they driving. The interview gain some information that can be used and doing some research about the problems they face. Besides that, internal sources like journal, article and books have been used to gain information about the bus cockpit arrangement such as ergonomics posture while driving.
For the ergonomic analysis, CATIA software have been used. The software will give result about the ergonomics analysis from the existing UTeM bus cockpit and new concept design of UTeM bus cockpit. The result for existing and new concept design will be used to compare to get the best ergonomics result.
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This research will be divided into six chapters. The first chapter is mainly about the introduction of the project, problem statement, objectives and lastly the project outline.
Chapter two is the literature review. Based on the references gathered (journals, books, websites, article etc.), this chapter will discuss the definition and introduction of ergonomics, bus driver distraction and bus cockpit arrangement. It will also discuss the method on how the research will be done based on the past researches.
Chapter three will be discussing about the review of the research methodology. This will include the design and framework of the study. This chapter will also discussing about the advantage and disadvantage of the methods chosen where ergonomomic analysis method and the drawing of the actual design of cockpit arrangement.
Chapter four is about the conceptual design. The new concept design will be drawn by using CATIA software and it will be analyzed to perfom the ergonomics analysis of the new concept of cockpit arrangement.
Chapter five is discussion of the project analysis. The result get from both actual and new concept design will be compared and discussed. This will include the setup for the data collection, the data collection table and the example of the data which had been taken in this chapter. The data result and the findings during the project research will be compared and discussed in details
In the last chapter, the conclusion and the recommendation will be reviewed. This chapter will concluded the project and give some suggestion will be given for future research. Figure 1.1 shows the outline of this project.
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Figure 1.1 Outline of project
Figure 1.2 shows the flow chart of this project. Each chapter of this project will based on the project flow chart. The chapters include in this project are literature review, existing design analysis, conceptual design, detail design, result and discussion and lastly the conclusion and recommendation of this project.
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Figure 1.2 Project Flow Chart Yes
No
Discussion and Recommendation
Report writing
Accept
Selection Design
Detail design ( CAD drawing )
Result Data processing Ergonomics Analysis Ergonomics Analysis
Conceptual design New design Existing design
CAD drawing
Data processing
Result
Checking and Improvement
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this project are listed sequently in the vertical axis and the estimated time to accomplish the task are shown along the horizontal axis of this Gantt chart.
Table 1.1 PSM 1 Gantt Chart PSM 1 Gantt Chart
Activity Week
1 2 3 4 5 6 7 8 9 10 11 12 13 14 Project Proposal
• Title Selection
• Supervisor Verification Chapter 1 : Introduction • Objective, Scope,
Problem Statement & Methodology
• Correction
Chapter 2 : Literature Review • Journal, Article & Books
review • Correction Seminar 1 (Poster) • Preparation • Submit
Chapter 3 : Methodology • Flow Chart of Project
process
• Process of Analysis • Correction
Seminar 2 (Presentation) • Preparation
• Presentation PSM 1 Report Drafting • Preparation
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this project are listed sequently in the vertical axis and the estimated time to accomplish the task are shown along the horizontal axis of this Gantt chart. To finished this project, the Gantt chart must followed.
Table 1.2 PSM 2 Gantt Chart
Activities PSM 2 (2012)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Chapter 4 :Conceptual
Design & Selection
Design Sketching Concept Evaluation Concept Selection
Detail Design Seminar 1 (Poster) -
PSM 2 Preparation Submit Chapter 5 : Results &
Analysis Ergonomics Analysis
Result Comparison Chapter 6 : Conclusion
and Recommendation Conclusion &
Recommendation Seminar 2 (Presentation)
- PSM 2 Preparation PSM 1 & 2 Report
Drafting Preparation Compile PSM 1
& PSM 2 Report PSM Submit
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made for UTeM’s driver bus used. Besides that, the design of cockpit arrangement must perform the new ergonomics design analysis to make a suitable, variable condition and comfortable design for UTeM’ driver bus.
The new ergonomics design of UTeM bus cockpit must do a comparison between the existing UTeM bus cockpit design to get the result that can make UTeM bus driver comfortable and can focus without no distraction when driving and not feel so tired to drive on long journey. This ergonomics design must be evaluated by using the CATIA ergonomics analysis to get the result of the new ergonomics design.
1.4 Methodology
Many methods have been used to gain an information about the UTeM bus cockpit arrangement. The method used are doing an interview with UTeM driver bus, and doing article review about the ergonomics function of the bus cockpit arrangement.
The interview done by do talk with UTeM driver bus to know what effect while they driving. The interview gain some information that can be used and doing some research about the problems they face. Besides that, internal sources like journal, article and books have been used to gain information about the bus cockpit arrangement such as ergonomics posture while driving.
For the ergonomic analysis, CATIA software have been used. The software will give result about the ergonomics analysis from the existing UTeM bus cockpit and new concept design of UTeM bus cockpit. The result for existing and new concept design will be used to compare to get the best ergonomics result.
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1.5 Project Outline
This research will be divided into six chapters. The first chapter is mainly about the introduction of the project, problem statement, objectives and lastly the project outline.
Chapter two is the literature review. Based on the references gathered (journals, books, websites, article etc.), this chapter will discuss the definition and introduction of ergonomics, bus driver distraction and bus cockpit arrangement. It will also discuss the method on how the research will be done based on the past researches.
Chapter three will be discussing about the review of the research methodology. This will include the design and framework of the study. This chapter will also discussing about the advantage and disadvantage of the methods chosen where ergonomomic analysis method and the drawing of the actual design of cockpit arrangement.
Chapter four is about the conceptual design. The new concept design will be drawn by using CATIA software and it will be analyzed to perfom the ergonomics analysis of the new concept of cockpit arrangement.
Chapter five is discussion of the project analysis. The result get from both actual and new concept design will be compared and discussed. This will include the setup for the data collection, the data collection table and the example of the data which had been taken in this chapter. The data result and the findings during the project research will be compared and discussed in details
In the last chapter, the conclusion and the recommendation will be reviewed. This chapter will concluded the project and give some suggestion will be given for future research. Figure 1.1 shows the outline of this project.
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Figure 1.1 Outline of project
Figure 1.2 shows the flow chart of this project. Each chapter of this project will based on the project flow chart. The chapters include in this project are literature review, existing design analysis, conceptual design, detail design, result and discussion and lastly the conclusion and recommendation of this project.
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Figure 1.2 Project Flow Chart Yes
No
Discussion and Recommendation
Report writing Accept
Selection Design
Detail design ( CAD drawing )
Result Data processing Ergonomics Analysis Ergonomics Analysis
Conceptual design Literature Review
New design Existing design
CAD drawing
Data processing
Result
Checking and Improvement
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Table 1.1 shows the Gantt chart for PSM 1. The tasks needed to complete this project are listed sequently in the vertical axis and the estimated time to accomplish the task are shown along the horizontal axis of this Gantt chart.
Table 1.1 PSM 1 Gantt Chart PSM 1 Gantt Chart
Activity Week
1 2 3 4 5 6 7 8 9 10 11 12 13 14 Project Proposal
• Title Selection
• Supervisor Verification Chapter 1 : Introduction
• Objective, Scope, Problem Statement & Methodology
• Correction
Chapter 2 : Literature Review
• Journal, Article & Books review
• Correction Seminar 1 (Poster)
• Preparation
• Submit
Chapter 3 : Methodology
• Flow Chart of Project process
• Process of Analysis
• Correction
Seminar 2 (Presentation)
• Preparation
• Presentation PSM 1 Report Drafting
• Preparation
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Table 1.2 shows the Gantt chart for PSM 2. The tasks needed to complete this project are listed sequently in the vertical axis and the estimated time to accomplish the task are shown along the horizontal axis of this Gantt chart. To finished this project, the Gantt chart must followed.
Table 1.2 PSM 2 Gantt Chart
Activities PSM 2 (2012)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Chapter 4 :Conceptual
Design & Selection
Design
Sketching
Concept Evaluation Concept Selection
Detail Design Seminar 1 (Poster) -
PSM 2
Preparation
Submit
Chapter 5 : Results &
Analysis
Ergonomics Analysis
Result
Comparison Chapter 6 : Conclusion
and Recommendation Conclusion &
Recommendation Seminar 2 (Presentation)
- PSM 2
Preparation PSM 1 & 2 Report
Drafting
Preparation Compile PSM 1
& PSM 2 Report PSM Submit