Designing press tool for carton finishing process to improve productivity and efficiency

Abstract

Using cardboard as packaging protects the product from damage while at the same time improving its appearance to attract the attention of customers. The packaging company, PT. XYZ, works manually without using machines or tools. As a result, inefficiencies tend to occur because workers waste time and energy. It also has the potential to cause extreme fatigue and workplace accidents. This research is a field of ergonomics research, the aim is to understand the physical complaints of workers, the work sequence of workers, to then design a helper tool and finally evaluate the work posture of workers, before and after repairs. To improve workers 'conditions, researchers collected workers' identities and analyzed their physical complaints using questionnaires, including Nordic Body Map, REBA analysis, OWAS analysis, MFA analysis, and measurement of right and left hand maps in standard time. We also identified workers' needs, initial specifications to conceptualize the design of assistive devices. We obtain the design concept by determining the final specifications and checking the data using CATIA software. The final REBA score after applying the helper press yields a score of 3 on pressing and folding cartons. Improvements also managed to eliminate lifting and lowering activities during the finishing process. Analysis result of the working conditions before and after implementation are as follows; cycle time decreased from 320.23 to 275 seconds (14.12%), normal time decreased from 336.24 to 299.75 seconds (11%), and standard time dropped from 437.11 to 374.69 seconds (14, 3%).