Analysis and Improvement of Working Postures in Cargo Securing Process During Outbound Shipment by Using Different Ergonomics Tools and Software

Abstract

The main objectives of this study were to identify the most problematic postures in hammering tasks performed at outbound shipment process within logistics through application of the computerized Classic Jack Software and Ergonomics analysis tools such as Rapid Entire Body Assessment (REBA), Safety and Ergonomics Risk Assessment (SERA) and Rapid Upper Limb Assessment (RULA) method, and to develop recommendations for improvement of working methods and workplaces. The manufacturer exports the product through sea containers, and it is very important to secure the product inside the container by nailing and lashing operation so that product will not get damaged during transportation. The lashing and nailing operations are required to secure product inside the container and both are below the knee level operations which are ergonomically not safe. The outbound shipment process ergonomics and productivity is improved by eliminating hammering operation and inefficiencies in the container loading and unloading process through designing the unique self-locking pallet which doesn’t need any securing operation like nailing and lashing. The “Lean and Triz” are employed to solve problems and improvements were recorded. The container loading time is reduced from 53.4 to 28.4 min for palletizing shipments hence productivity improved by 46.81%. SERA score reduced from 48 to 1. REBA score reduced from 11 to 3. RULA score reduced from 7 to 2. The overall increase in the productivity of outbound shipment by ~47% and reduction in the ergonomics risk to bare minimum.