PPT Thesis - Giorgio Sudibyo

S W I S S G E R M A N U N I V E R S I T YDESIGNING AND DEVELOPING AN ASSEMBLY

FIXTURE USING ERGONOMIC APPROACH (CASE STUDY: CAR ENGINE ASSEMBLY)

A Thesis Presentation By

Giorgio Sudibyo

In Partial Fulfillment of the Requirements forBACHELOR’S DEGREE

ININDUSTRIAL ENGINEERING

SWISS GERMAN UNIVERSITYEduTown BSDCityTangerang – 15339

INDONESIA

Title Page

S W I S S G E R M A N U N I V E R S I T Y

18/07/16DESIGNING AND DEVELOPING AN ASSEMBLY FIXTURE USING ERGONOMIC APPROACH (CASE STUDY: CAR ENGINE ASSEMBLY) – GIORGIO SUDIBYO – ENGINEERING & IT 2

OVERVIEW

• Background• Problem Definition• Objectives• Literature Review• Methodologies• Results and Discussion• Conclusions and Recommendation


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BACKGROUND

Competition of manufacturers with the aim of fulfilling market demand shows that unique techniques and approach are being considered to optimize productivity. One of such method involves the implementation and development of assembly fixture. This specific assembly tool supports an assembly task by improving worker ergonomics and generates a consistent level of accuracy to the work

DESIGNING AND DEVELOPING AN ASSEMBLY FIXTURE USING ERGONOMIC APPROACH (CASE STUDY: CAR ENGINE ASSEMBLY) – GIORGIO SUDIBYO – ENGINEERING & IT18/07/16


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PROBLEM DEFINITION

Problem Statement Hypothesis• A proper designed assembly fixture

reduces worker posture stress possibility

• Ergonomic score (RULA and OWAS) of the postures analyzed are significantly reduced by the implementation of assembly fixture

• Assembly fixture developed in this thesis is able to simplify the work performed by the worker and reduce the force required to perform the tasks

• Designing an assembly fixture without ergonomic consideration could increase the possibility of worker injury

• Manual material handling processes has been one of the major causes of worker fatigue and injury

• Designing a fixture without any methodology increases the material handling time

18/07/16DESIGNING AND DEVELOPING AN ASSEMBLY FIXTURE USING ERGONOMIC APPROACH (CASE STUDY: CAR ENGINE ASSEMBLY) – GIORGIO SUDIBYO – ENGINEERING & IT


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OBJECTIVES• An assembly fixture design alternative must be provided based on the analysis of

assembly fixture implementation in car engine assembly station

• Identifying worker posture while performing car engine assembly tasks by using ergonomic evaluation methodology in Human Jack Simulation

• Assessment of working posture performed in a car engine assembly station using Human Jack Simulation

• Constructing an analysis on the function and components of the assembly fixture used in car engine assembly station



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THESIS FOUNDATION

A Concrete Foundation is Built to establish the key elements associated with an Assembly Fixture

“ Fixtures are to hold workpieces stable and constraint without any movement during a process” - (Hashemi, 2014)



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METHODOLOGIES


The Methodology designed for this thesis is adapted from Spiral Model developed by Barry Boehm

Ergonomic Evaluation methodology of RULA and OWAS are adapted to enhance the risk analysis phase


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Assembly Fixture AnalysisLocating Points Clamps Vice Hand Lever Base Plate

Each components in an assembly fixture performs specific function

Even though all assembly fixture may have different components, the mechanism in the respective fixture should support each other



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ASSEMBLY FIXTURE EVALUATION

Engine Drawing Illustration Assembly Fixture Drawing Illustration

Simulation environments was

created using illustration of the

engine and assembly fixture

The design was adopted from a car engine assembly

station



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CAR ENGINE ASSEMBLY PROCESS ANALYSIS

Both task are selected to represent the capabilities of the assembly fixture

The highlighted cell represents the position where ergonomic evaluation are performed and simulated



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HUMAN JACK SIMULATION REPORT


The lower the ergonomic score resulted in lower negative impact on the worker posture


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ASSEMBLY FIXTURE IMPLEMENTATION ALTERNATIVE

Time (In Minutes)Assembly Process 1 2 3 4 5 6 7 8

Assembling the power supply frame by attaching the bolts to the rear speaker body Assembling the Crossover board to the rear speaker body Assembling the speaker to the front body using M2 screws for Speaker Body A Assembling the front and rear body of speaker A Assembling the speaker to the front body using M2 screws for Speaker Body B Assembling the front and rear body of speaker B


A more thorough development of the assembly fixture is performed by exploring the capability alteration

Different product characteristic drives the author to select a PC speaker as the design alternative


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CONCLUSIONS

The implementation of assembly fixture in a car engine assembly line has significantly reduced the injury possibility during assembly tasks

The implementation of assembly fixture has reduced the posture score assessed using OWAS method by 31%, while RULA method shows that the posture performed are cut down by 42%

Performing car engine assembly processes without the use of an assembly fixture have several negative outcomes, especially to the trunk, arms, and neck of the worker

Unfortunately, the assembly fixture in PT. XYZ has not yet fully resolve the ergonomic of the upper limb (the scores are still marked yellow, which means that it needs to be evaluated)

Implementation of an assembly fixture can reduce the complexity and increase accuracy by optimizing PC speaker assembly process



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RECOMMENDATION FOR FURTHER RESEARCH


Exploring more capabilities of the assembly fixture by experimenting on other product characteristics

Assessing worker postures using ergonomic evaluation methods that considers an entire body, rather than focusing solely on the upper body part

Perform an observation to an actual PC speaker assembly line, and simulate the whole assembly process using Human Jack SimulationAn analysis on other variant of fixtures are recommended. Machining fixtures and inspection fixtures are comprised as typical fixtures used in factories


Thank YouVielen Dank Terima Kasih


Giorgio Sudibyo

Industrial Engineering

Batch 2012

PPT Thesis - Giorgio Sudibyo

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