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Estación de Trabajo de Análisis en La Industria Manufacturera Utilizando El Método Del Índice de Acción Repetitiva Ocupacional (OCRA) Para Reducir El Riesgo de Trastornos Musculoesqueléticos Relacionados Con El t
Estación de Trabajo de Análisis en La Industria Manufacturera Utilizando El Método Del Índice de Acción Repetitiva Ocupacional (OCRA) Para Reducir El Riesgo de Trastornos Musculoesqueléticos Relacionados Con El t
Estación de Trabajo de Análisis en La Industria Manufacturera Utilizando El Método Del Índice de Acción Repetitiva Ocupacional (OCRA) Para Reducir El Riesgo de Trastornos Musculoesqueléticos Relacionados Con El t
1051/e3sconf/202342601080
ICOBAR 2023
Abstract. According to analysis of Global Burden of Disease (GDB) 2019 data, approximately 1.71 billion
people have musculoskeletal disorder (MSDs) worldwide. It could cause constant pain and limitations in
mobility, dexterity, and reducing people’s ability to work. Musculoskeletal disorders can be caused by
repetitive and heavy work activities. On Hub 2/3 work station, production is carried out by machining
processes using CNC machines, drilling machines and tapping machines with predetermined target outputs.
In this process, there are repetitive actions which have risk of musculoskeletal disorders. By using the OCRA
method and calculating the OCRA Index value, the operator 1 is in the red zone, then operator 2 and operator
3 are in the yellow zone which means the work conditions at workstations must be improved. The objective
of this paper is to analyze Hub 2/3 workstations in order to minimize the risk of musculoskeletal disorders
for each operator. The proposed improvement are given to fulfill the objectives of this paper. The results of
the OCRA calculations with the assumption that all proposed improvements are applied are smaller than the
previous calculations which means the risk of musculoskeletal disorders is reduced.
© The Authors, published by EDP Sciences. This is an open access article distributed under the terms of the Creative Commons Attribution License 4.0
(https://creativecommons.org/licenses/by/4.0/).
E3S Web of Conferences 426, 01080 (2023) https://doi.org/10.1051/e3sconf/202342601080
ICOBAR 2023
sequences can be optimized. The work should organize to The overall value of ATA calculated from actual
make the task duration not too long, the frequency of action performed by operator per shift. At any rate: [3]
movements and or force exertions should not too high and
can be adjusted by the worker to his/her own individual ATA ¦ ( FJ uD J ) (2)
capabilities, and there should be sufficient recovery
Dj = net duration (in minutes) of task j
periods. [9]
Fj = average frequency of action per minute of task j
({number of technical action * 60} / total net cycle
2 Methods time duration)
This study uses quantitative and qualitative methods in In order to calculating RTA, there are risk factors or
obtaining the data. Some data obtained from the company multiplier that must be considered such as force
such as process production data, duration of working multiplier, posture multiplier, repetitive multiplier,
hours and rest time, layout of Hub 2/3 workstation. Other additional multiplier, duration multiplier and recovery
data was obtained by observing the conditions of work multiplier.
environment, work attitude, and working posture of Hub Force multiplier determined by interviewing workers
2/3 operators then assigning a score to the results. There about the force exerted by workers while doing their
are potential confounding variables that may have work. The interview results are then converted into values
influenced the results of this study such as the posture of based on the Borg CR-10 scale so that FoM values can be
operator, the fitness and the strength of operator. determined by calculating the duration of each force
The OCRA index is produced by the ratio of the issued. Table 1 proposes a model for applying the Borg
absolute number of actual technical actions (ATA) scale to gather information about perceived physical
currently performed in a work shift to the corresponding exertion and Table 2 used to assign the force multiplier
number of recommended technical actions (RTA). (FoM).
2
E3S Web of Conferences 426, 01080 (2023) https://doi.org/10.1051/e3sconf/202342601080
ICOBAR 2023
Figure 4 shows the postural involvement of the hand Table 8. Repetitive multiplier [2]
and fingers which categorized as awkward posture and the
score of the posture are shown in Table 6. Scenario High Repetitive Moderate Repetitive
Identical technical Identical technical
actions or groups of actions or groups of
identical technical identical technical
actions repeated for actions repeated for
almost the entire over 50% of the cycle
cycle (more than time.
80%).
Fig. 4. Awkward hand and fingers posture/ movement [2]
Static postures Static postures
Table 7 shows the elements required to go from the sustained for over sustained for over
descriptive effort score to the corresponding PoM. This 80% of the cycle time 50% of the cycle time
table will be used for each segment of the upper limb and (e.g., pro-longed (e.g., prolonged
separately for each limb. The most penalizing posture gripping of a knife or gripping of a knife or
multiplier (PoM) is used, corresponding to the highest screwdriver). screwdriver).
postural effort from among the scores for the hand, wrist, Extremely short Extremely short
elbow, or shoulder of each limb. cycles lasting less cycles lasting less
than 8 s, featuring than 15 s, featuring
Repetitive multiplier can be determined by two different
actions that involve actions that involve
scenarios as shown in Table 8. the upper limbs. the upper limbs.
Repetitive
Multiplier 0.7 0.85
(ReM)
3
E3S Web of Conferences 426, 01080 (2023) https://doi.org/10.1051/e3sconf/202342601080
ICOBAR 2023
Additional multiplier can be by observing the work Table 9. Additional risk factor multiplier [2]
station whether there are other factors that interfere with
Score 0-4 4-7 8-11 12-15
the work process such as the working environment Additional
(lighting, vibration, temperature, noise) which is not Multiplier 1 0.95 0.90 0.85 0.80
good. In addition, observations were made on the personal (AdM)
protective equipment whether it cause more difficult to
work, risks workers exposure to cold from the ambient Duration multiplier determined by obtaining the total
temperature or from tools or materials.Table 9 shows the net duration value when performing repetitive actions,
elements used to assign the additional risk factor namely by subtracting the duration of one full shift with
multiplier (AdM), based on the descriptive classifications breaks, lunch, movements that are categorized as recovery
presented. periods and the total duration of movements that do not
include repetitive movements. Table 10 provides the
parameters for dealing with the duration multiplier
(DuM).
Table 10. Duration multiplier [2]
Duration of
performing
121-180 181-240 241-300 301-360 361-420 421-479 480-540 541-600 601-660 661-720 >720
repetitive
action / shift
Duration
Multiplier 2 1.7 1.5 1.3 1.2 1.1 1 0.83 0.66 0.5 0.35 0.25
(DuM)
Recovery multiplier determined based on the longest Table 12. OCRA index classification [2]
working time performed by the worker without adequate Zone OCRA Risk Suggested
recovery. Table 11 illustrates the scores for ReM. Index Classification Action
Value
After all of risk factors or multipliers value Green Up to Optimal None
determined. The overall number of RTA is calculated by 1.5
following general formula: Green 1.6-2.2 Acceptable None
Yellow 2.3-3.5 Borderline Recheck, if
RTA
n
> @
¦ CF u FoMj u PoMj uRe Mj u Ad Mj u D j u RcM u Du M
j 1
(3) possible
improve
working
N = number of repetitive tasks per shift conditions
J = generic (j-th) repetitive task performed by the upper Red- 3.6-4.5 Slight improve
limbs Low working
CF = RTA frequency (30) per minute under reference conditions;
conditions health
FoMj; PoMj; ReMj; AdMj = multipliers, chosen in relation to the surveillance;
behavior of the force, posture, repetitiveness, and training
additional risk factors embedded in each j-th task under Red- 4.6-9.0 Medium improve
examination Medium working
Dj = duration (in minutes) of each j-th repetitive task conditions;
RcM= multiplier for the “lack of recovery period” risk factor health
(one only for jobs with 1 or more repetitive tasks) surveillance;
DuM= multiplier that takes into account the net duration of training
repetitive tasks (one only for jobs with 1 or more Red- More High improve
repetitive tasks) High than 9.0 working
conditions;
Furthermore, the final value of OCRA index are health
classified on Table 12 to determine the suggested action. surveillance;
training
4
E3S Web of Conferences 426, 01080 (2023) https://doi.org/10.1051/e3sconf/202342601080
ICOBAR 2023
The last step are analyze each risk factor to find Table 14. Actual Technical Actions Operator 1, 2 & 3
potential improvement to redesign Hub 2/3 in order to Operator 1 Operator 2 Operator 3
reducing or minimize the risk of UL-WMSD for each Left Right Left Right Left Right
operator. No. Of
Technical 23 53 17 32 5 31
Action
3 Results and discussions Total Net
114.75 99.8 108.15
Cycle Time
Frequency 12.03 27.71 10.22 19.24 2.86 16.61
Data collection was carried out at Hub 2/3 workstations
ATA 5532.0 12747 4701.4 8849. 1276. 7911.
with 3 operators operating 5 machines. Operator 1 3 .71 0 70 01 23
operates CNC Lathe machines 1,2 & 3. Operator 2
operates a drill machine and Operator 3 operates a tap
machine. The data obtained from observations are cycle 3.2 Factor multiplier of RTA
time data and technical actions carried out by each
operator which are recorded with a camera and interview In the calculation of RTA required multiplier factor of
with the operator. force, posture, repetitive, additional, duration of repetitive
Table 13 show the data of technical action of left upper action and recovery.
limb and right upper limb on Operator 1.
3.2.1 Force Multiplier
Table 13. Technical action Operator1
The force multiplier obtained with the use of Borg CR-10
Left Right scale are shown in Table 15 and assign the multiplier on
Technical No. Of No. Of Table 16.
No.
Action Duration Technica Duration Technical
l Action Action
Loading
1 material to 3.2 2 4.63 3 Table 15. Assessment of Borg CR-10 Scale right upper limb of
Machine-1 Operator 1
Machining
2 process on 0 0 13.92 7 Borg Duration
Machine-1 Technical CR-10 Action Weighted
Microphase
Manual Action Scale with Force
3 2.17 2 8.59 5 Score Force
process 1
Unloading Machining Put material on
7 1.8 10.80
& loading process on Machine-1
4 3.27 2 3.27 2 Machine-1
material to Adjust material
Machine-2 2 3.61 7.22
position
Machining Close machine door 2 1.92 3.84
5 process on 3.89 2 6.7 4 Press button on
Machine-2 0.5 1.21 0.61
machine
Manual Pick the air gun 0.5 0.86 0.43
6 1.23 1 9.18 4
process 2 Spray work piece
Unloading 1 4.13 4.13
with air gun
& loading Put the air gun 0.5 0.39 0.20
7 0 0 4.35 4
to machine
3
8
Manual
7.57 3 4.78 3
Table 16. Assessment of force multiplier of Operator 1
process 3
Quality Weighted Force
9 4.12 3 18.66 8 No. Technical Action
check 1 Left Right
Write Loading material to
1 22.40 35.61
10 production 1.91 3 5.52 4 Machine-1
code Machining process on
2 0 30.94
Quality Machine-1
11 6.22 3 12.77 7 3 Manual process-1 15.19 27.74
check 2
Move work Unloading & loading
4 22.89 22.89
12 piece to 7.97 1 7.97 1 material to Machine-2
Operator 2 Machining process on
5 5.14 5.01
Waiting for Machine-2
13 machining 8 1 8 1 6 Manual process-2 0.62 36.73
process Unloading & loading to
7 0 30.45
TOTAL 49.55 23 108.34 53 machine-3
8 Manual process-3 13.24 3.61
9 Quality check-1 9.58 28.50
3.1 Actual Technical Actions (ATA) calculations 10 Write production code 3.57 4.83
11 Quality check-2 19.76 10.91
The data of technical action that has been obtained, then Move work piece to
12 15.94 15.94
Operator 2
able to be processed to obtain the frequency value and Waiting for machining
ATA which shown in Table 14. 13 0 0
process
TOTAL 128.325 260.66
AVERAGE 1.11 2.27
Force Multiplier (FoM) 0.75 0.55
5
E3S Web of Conferences 426, 01080 (2023) https://doi.org/10.1051/e3sconf/202342601080
ICOBAR 2023
Flexion-extension
Pronation >60°
Radial deviation
Flexion abduction
Supination >60°
Ulnar deviation
Extension >20°
Extension >45°
Small finger
Narrow grip
Palmar grip
movements
Abduction
Hook grip
(1.5 cm)
45°-80°
5 cm)
>60°
Pinch
>15°
>20°
>80°
Total
4.42 0 0 0 0.76 0 0 0 0.83 2.96 30.68 21.68 0 8.54 0 17.18
duration
Total net
cycle 114.75
time
%
duration 0.72 2.58 26.74 18.89 7.44
3.85% 0 0 0 0.66% 0 0 0 0 0 14.97%
of cycle % % % % %
time
Score 2 0 0 0 0 0 00 0 0 0.25 1 1.3 0 0.4 0 1.3
Group
2 0 0.25 4
score
Multiplier 1 1 1 0.7
Posture
Multiplier 0.7 (choose the worse between shoulder, elbow, wrist and hand and fingers)
(PoM)
09.40 12.30
According to the data obtained. There are no additional 07.00 08.00 09.00 10.00 11.00 12.00 13.00 14.00 15.00 16.00
factors that affect the risk of UL-WMSD of the workers = Process time = Recovery time
Operator 1, 2 & 3. Therefore, the additional multiplier Fig. 5. Distribution of recovery time
value is 1.
According to Figure 5, the number of hours without
3.2.5 Duration multiplier adequate recovery are 3.5 hours from 12.30 until 16.00.
Therefore, the recovery multiplier is 0.65.
According to the data obtained. Duration of shift-1
workstation Hub 2/3 area 540 minutes with detail
description shown in Table 19. 3.3 Recommended technical action (RTA)
calculations
The overall calculation of the number of RTA is used to
determine the recommended technical measures. The
results are shown in Table 20.
6
E3S Web of Conferences 426, 01080 (2023) https://doi.org/10.1051/e3sconf/202342601080
ICOBAR 2023
Table 20. Recommended technical action (RTA) of Operator back support for operator, the score will be reduced
1, 2 & 3 because back support can reduce low back injuries by
Operator 1 Operator 2 Operator 3 34% [10].
Left Right Left Right Left Right
CF 30 30 30 30 30 30
FoM 0.75 0.55 0.75 0.65 1 0.75 4.4 OCRA index after improvement
PoM 1 0.7 1 0.66 1 0.7
ReM 1 1 1 1 1 0.7 After improve workstation using OCRA index, the
AdM 1 1 1 1 1 1 proposed improvement has been implemented and be
D 460 460 460 460 460 460
shown in Table 22.
RcM 0.65 0.65 0.65 0.65 0.65 0.65
DuM 1 1 1 1 1 1 Table 22. OCRA Index after improvement
RTA 6727.50 3453.45 6727.5 3848.13 8970 3296.48
Operator 1 Operator 2 Operator 3
Left Right Left Right Left Right
5532. 12747.7 4701.4 8849.7 1276.0 7911.2
3.4 OCRA Index calculations ATA
03 1 0 0 1 3
7762. 5123.2
The final step in data processing on the OCRA Index is to RTA 4709.25 7762.5 10350 7762.5
50 5
calculate the value of the OCRA Index which is done by OCRA
0.71 2.71 0.61 1.73 0.12 1.02
comparing the results of the value of the number of actual Index
technical actions (ATA) and the overall value of the
number of reference technical actions (RTA). The results 5 Conclusion
are shown in Table 21.
Table 21. OCRA index of Operator 1, 2 & 3 The results of the OCRA calculations were obtained 0.82
on left hand of operator 1 and 3.69 on right hand of
Operator 1 Operator 2 Operator 3
operator 1, 0.70 on left hand of operator 2 and 2.30 on
Left Right Left Right Left Right
5532 12747.7 4701.4 8849.7 1276.0 7911.2 right hand of operator 2, 0.14 on left hand of operator 3
ATA and 2.40 on right hand of operator 3. Therefore operator
.03 1 0 0 1 3
RTA
6727
3453.45 6727.5
3848.1
8970
3296.4 1 is classified in the red zone, operator 2 and operator 3
.50 3 8 are classified in the yellow zone which means the work
OCRA
Index
0.82 3.69 0.70 2.30 0.14 2.40 conditions at workstations must be improved. After
improvement, OCRA index were obtained 0.71 on left
hand of operator 1 and 2.71 on right hand of operator 1,
4 Proposed Improvements 0.61 on left hand of operator 2 and 1.73 on right hand of
operator 2, 0.12 on left hand of operator 3 and 1.02 on
Proposed improvements are given to reduce the value of right hand of operator 3. From these results it can be seen
the OCRA index so as to reduce the risk of workers the OCRA index after improvement are lower than before
against UL-WMSD. improvement. It means the risk of musculoskeletal
disorders for each operator on Hub 2/3 work station is
4.1 Proposed recovery time reduced. In other words the Hub 2/3 work station is more
ergonomic.
The current workstation has 2 rest periods with numbers According on the results of the analysis, the longer
of hours without adequate recovery period for 3.5 h. operator perform works without adequate recovery, the
Figure 6 show the proposed distribution of recovery time longer operator sustain static postures, the higher force
which has 3 rest periods with numbers of hours without used to perform works, then the risk of musculoskeletal
adequate recovery period for 2.5 h. Therefore, the RcM disorders for operator are higher.
value becomes 0.7. After this research, there is a potential for future
09.30 11.40 14.30
research to analyze work equipment such as checking
09.40 12.20 14.40
tables, conveyor tables, raw material pallet and finished
07.00 08.00 09.00 10.00 11.00 12.00 13.00 14.00 15.00 16.00
goods pallet using the Recommended Weight Limit
method to maximize the value of force multiplier.
= Process time = Recovery time
References
4.2 Proposed install flexible hose in Machine5
1. A. Cieza et al, Global estimates of the need for
In the process of operator 3, there are a posture gripping rehabilitation based on the Global Burden of
the air gun for 83.14% of the cycle time. by installing a Disease study 2019: a systematic analysis for the
flexible hose on Machine5 then this can be eliminated so Global Burden of Disease Study 2019, The Lancet,
that the ReM and PoM value decreased. 396, (2020)
2. D. Colombini and E. Occhipinti, Management of
4.3 Proposed use of back support for operators Repetitive Actions A Guide for Applying the OCRA
System (Occupational Repetitive Actions), Boca
The work piece weight of 15.2 kg makes the Borg CR-10 Raton: CRC Press (2017)
score 7 when lifting & placing the work piece. By using
7
E3S Web of Conferences 426, 01080 (2023) https://doi.org/10.1051/e3sconf/202342601080
ICOBAR 2023