A Feasibility Study on the Conversion from Manual to Semi-Automatic Material Handling in an Oil and Gas Service Company
In manufacturing companies, manual material handling (MMH) involves lifting, pushing, pulling, carrying, moving, and lowering objects, which can lead to musculoskeletal disorders (MSDs) among workers, resulting in high labor costs due to excessive overtime incurred for manual product preparation. Th...
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| Format: | Article |
| Language: | English |
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MDPI AG
2023-03-01
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| Series: | Safety |
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| Online Access: | https://www.mdpi.com/2313-576X/9/1/16 |
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| author | Adi Saptari Poh Kiat Ng Michelle Junardi Andira Taslim |
| author_facet | Adi Saptari Poh Kiat Ng Michelle Junardi Andira Taslim |
| author_sort | Adi Saptari |
| collection | DOAJ |
| description | In manufacturing companies, manual material handling (MMH) involves lifting, pushing, pulling, carrying, moving, and lowering objects, which can lead to musculoskeletal disorders (MSDs) among workers, resulting in high labor costs due to excessive overtime incurred for manual product preparation. The aim of this study was to show how ergonomic measures were used to reduce the risk of MSDs and to reduce operating costs in the warehouse department of an oil and gas service company. A preliminary study using the Nordic Body Map survey showed that the workers experienced pain in various parts of the body, indicating the presence of MSDs. The researchers then used methods such as the Rapid Upper Limb Assessment (RULA), Rapid Entire Body Assessment (REBA), and National Institute for Occupational Safety and Health (NIOSH) assessments to verify whether the MMH activities had an acceptable level of risk. The results revealed that certain manual material handling (MMH) activities were assessed as low–very high risk, with RULA scores ranging from 3 to 7 and REBA scores ranging from 4 to 11. An immediate solution was to replace the manual process with a semi-automatic process using a vacuum lifter. A feasibility study was conducted using the net present value (NPV), internal rate of return (IRR), and payback period to justify the economic viability of the solution. The analysis indicated that implementing the vacuum lifter not only mitigated the risk of MSDs but also reduced the operating costs, demonstrating its viability and profitability. Overall, this study suggests that implementing a vacuum lifter as an assistive device in the warehouse would be a beneficial investment for both the workers and the company, improving both well-being and finances. |
| first_indexed | 2024-03-11T05:57:11Z |
| format | Article |
| id | doaj.art-4ec9ab6c21344e5aa6714e8a56cf20df |
| institution | Directory Open Access Journal |
| issn | 2313-576X |
| language | English |
| last_indexed | 2024-03-11T05:57:11Z |
| publishDate | 2023-03-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Safety |
| spelling | doaj.art-4ec9ab6c21344e5aa6714e8a56cf20df2023-11-17T13:42:09ZengMDPI AGSafety2313-576X2023-03-01911610.3390/safety9010016A Feasibility Study on the Conversion from Manual to Semi-Automatic Material Handling in an Oil and Gas Service CompanyAdi Saptari0Poh Kiat Ng1Michelle Junardi2Andira Taslim3Department of Industrial Engineering, President University, Jababeka Education Park, Jl. Ki Hajar Dewantara, RT.2/RW.4, Mekarmukti, Cikarang Utara, Bekasi Regency, Cikarang 17530, West Java, IndonesiaFaculty of Engineering and Technology, Multimedia University, Jalan Ayer Keroh Lama, Bukit Beruang 75450, Melaka, MalaysiaDepartment of Industrial Engineering, President University, Jababeka Education Park, Jl. Ki Hajar Dewantara, RT.2/RW.4, Mekarmukti, Cikarang Utara, Bekasi Regency, Cikarang 17530, West Java, IndonesiaDepartment of Industrial Engineering, President University, Jababeka Education Park, Jl. Ki Hajar Dewantara, RT.2/RW.4, Mekarmukti, Cikarang Utara, Bekasi Regency, Cikarang 17530, West Java, IndonesiaIn manufacturing companies, manual material handling (MMH) involves lifting, pushing, pulling, carrying, moving, and lowering objects, which can lead to musculoskeletal disorders (MSDs) among workers, resulting in high labor costs due to excessive overtime incurred for manual product preparation. The aim of this study was to show how ergonomic measures were used to reduce the risk of MSDs and to reduce operating costs in the warehouse department of an oil and gas service company. A preliminary study using the Nordic Body Map survey showed that the workers experienced pain in various parts of the body, indicating the presence of MSDs. The researchers then used methods such as the Rapid Upper Limb Assessment (RULA), Rapid Entire Body Assessment (REBA), and National Institute for Occupational Safety and Health (NIOSH) assessments to verify whether the MMH activities had an acceptable level of risk. The results revealed that certain manual material handling (MMH) activities were assessed as low–very high risk, with RULA scores ranging from 3 to 7 and REBA scores ranging from 4 to 11. An immediate solution was to replace the manual process with a semi-automatic process using a vacuum lifter. A feasibility study was conducted using the net present value (NPV), internal rate of return (IRR), and payback period to justify the economic viability of the solution. The analysis indicated that implementing the vacuum lifter not only mitigated the risk of MSDs but also reduced the operating costs, demonstrating its viability and profitability. Overall, this study suggests that implementing a vacuum lifter as an assistive device in the warehouse would be a beneficial investment for both the workers and the company, improving both well-being and finances.https://www.mdpi.com/2313-576X/9/1/16manual handlingmusculoskeletal diseasesrisk assessmentergonomicsfeasibility studiesoccupational health |
| spellingShingle | Adi Saptari Poh Kiat Ng Michelle Junardi Andira Taslim A Feasibility Study on the Conversion from Manual to Semi-Automatic Material Handling in an Oil and Gas Service Company Safety manual handling musculoskeletal diseases risk assessment ergonomics feasibility studies occupational health |
| title | A Feasibility Study on the Conversion from Manual to Semi-Automatic Material Handling in an Oil and Gas Service Company |
| title_full | A Feasibility Study on the Conversion from Manual to Semi-Automatic Material Handling in an Oil and Gas Service Company |
| title_fullStr | A Feasibility Study on the Conversion from Manual to Semi-Automatic Material Handling in an Oil and Gas Service Company |
| title_full_unstemmed | A Feasibility Study on the Conversion from Manual to Semi-Automatic Material Handling in an Oil and Gas Service Company |
| title_short | A Feasibility Study on the Conversion from Manual to Semi-Automatic Material Handling in an Oil and Gas Service Company |
| title_sort | feasibility study on the conversion from manual to semi automatic material handling in an oil and gas service company |
| topic | manual handling musculoskeletal diseases risk assessment ergonomics feasibility studies occupational health |
| url | https://www.mdpi.com/2313-576X/9/1/16 |
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