v
TABLE OF CONTENT
Abstrak
i Abstract
ii Dedication
iii Acknowledgement
iv Table of Content
v List of Tables
viii List of Figures
ix List Abbreviations, Symbols and Nomenclatures
xi
CHAPTER 1: INTRODUCTION 1
1.1 Background of Study 1
1.2 Problem Statement 3
1.3 Objectives 6
1.4 Scope of Study 7
CHAPTER 2: LITERATURE REVIEW 8
2.1 The Ergonomic Factors that Influenced Posture of the Welder and Weld Quality in SMAW Process
8 2.1.1 Ergonomics Risk Factors
8 2.1.2 Shielded Metal Arc Welding SMAW
13 2.1.3 Method to Determine the Ergonomics Factors
15 2.1.3.1 Observation
16 2.1.3.2 Questionnaire Survey
16 2.1.3.3 Pilot Study
18 2.2 Analysis of the Effect of Ergonomic Factors on the Welder’s
Posture and Weld Quality 19
2.2.1 Design of Experiment DoE 19
2.2.2 Rapid Upper Lumbar Assessment 21
2.3 Redesign SMAW Workstation 23
vi 2.3.1 Quality Function Deployment QFD
23 2.3.2 Concept Screening Method
25 2.3.3 Ergonomics Design Software
26 2.4 Differences between Previous Studies and Current Study
27 2.5 Summary
29
CHAPTER 3: METHODOLOGY 30
3.1 Determine the Ergonomic Factors that Influenced Posture of the Welder and Weld Quality in SMAW Process
30 4.1.1 Observation
30 4.1.2 Questionnaire Survey
32 4.1.3 Literature Review
33 3.2 Analyse the Effect of Ergonomic Factors on the Welder’s Posture
and Weld Quality 34
3.2.1 Selection of Variables 34
3.2.1.1 Pilot Study 34
3.2.1.2 Actual Experiment using Design Expert Software 35
3.2.2 Data Analysis using Design Expert Software 39
3.2.3 Assessment of Working Posture 41
3.3 Redesign SMAW Workstation 45
3.3.1 House of Quality 45
3.3.2 Concept Screening Method 49
3.3.3 Ergonomics Design Software 52
3.4 Summary 53
CHAPTER 4: RESULTS DISCUSSION 55
4.1 Ergonomic Factors at SMAW Workstation 55
4.1.1 Observation 55
4.1.2 Background Information of Respondents 57
4.1.3 Ergonomics Factors Presented at SMAW Workstation 57
4.2 Effect of Ergonomic Factors on the Welder’s Posture and Weld Quality
59 4.2.1 Comfort Level While Using SMAW Workstation
59
vii 4.2.2 Rapid Upper Lumbar Assessment
60 4.2.3 Design of Experiment DoE
61 4.2.3.1 Descriptive Statistics
62 4.2.3.2 Analysis of Variance ANOVA
62 4.2.3.3 Optimisation
67 4.3 Redesign SMAW Workstation
69 4.3.1 Ergonomic Design Requirements for SMAW Workstation
69 4.3.2 House of Quality
71 4.3.3 Concept Screening Method
74 4.3.4 Final Design
76
CHAPTER 5: CONCLUSION FUTURE WORK 79
