An ergonomics study in a Thai traditional gypsum powder dropping process to design a prototype of a dropping machine

This research aims to analyze motions by using an ergonomics study in a Thai traditional gypsum powder (Panglum) dropping process for designing a prototype of a Panglum dropping machine. An analysis of the dropping process points out that the dropping process does not have any work standards, there are lots of wastes of non-productive motions, and operators always have fatigue problems because of a repetition of activities in the workflow. An ergonomics study is used as a research tool to analyze the causes of the problems. The risk assessment, by using a Rapid Entire Body Assessment ( REBA), results that the current Panglum dropping process has a very high risk, as a level of 11. This means the process has to be improved immediately. Additionally, the process study shows that there are lots of defects that are divided into Grade B and Grade C products. These grade B and C products result in an opportunity cost of about 988,000 Thai baht per month. To reduce risk and increase productivity in the Panglum dropping process, researchers use a principle of machine design and ergonomics design to analyze all factors involved in the process for designing a prototype of a semi-automatic dropping machine. A feasibility study shows that the use of this dropping machine can help to reduce risks and to increase the quantity of Grade A products. This means the process can respond more to the high demands of a high-end Panglum market. An economic feasibility study shows that a profit per month will be increase about 142. 61% and a payback period of the dropping machine is about 5 months.