An empirical study on CSFs for pre-development processess implementation at SMEs in Malaysia

New product development processes and product innovation in manufacturing organization is promoting an environment of competitive advantage for organization that can make adequate use of the processes.However, Malaysian SMEs is facing with huge obstacles in implementing various product innovation activities particularly the pre development processes due to scarce financial resources, manpower, knowledge, and expertise. In fact, the previous research result shows that more focus were given to the discussing about critical success factor for pre-development process implementation in large organizations compared with SMEs.In reality, SMEs having different characteristics compared with large organizations.Primarily, this study is performed, to identify the critical factors which are able to increase the successful implementation of pre-development in SMEs. In achieving the research objective, Delphi techniques have been used for confirmation to identify critical factors based on previous literature's, whether those factors are suitable with the characteristics and surrounding nature of SMEs.The survey form were sent to 35 respondents whose expertise are in the field of pre-development process.However, the researcher managed to interview 20 expert panels.The result of the research showed that top management factor, team leaders and members of the team were the main contributors leading the successfulness of the pre-development process in the SMEs organization worthwhile training program factor’s effect is low

Measuring pressure interface of local car seats under static and dynamic circumstances: a comparative study

Measuring discomfort towardthe car seat is important as the act of driving requires a driver to remain at the car seat while controlling the car. The seat condition, including sitting position as well as the driver’s posture can lead to discomfort and fatigue. The objective of this study is to investigate a driver’s pressure distribution in static and dynamic circumstances for two types of cars; the sedan and compact car. This study involved both subjective and objective evaluations of 12 respondents. For the subjective evaluation, the Visual Analog Scales (VAS) were used to obtain respondents' perception of discomfort. For the objective evaluation, pressure distribution readings of the seat interface were obtained using piezo capacitive sensors. The findings showed that the highest pressure was recorded for the compact car. Furthermore, the static circumstance showed greater pressure compared to the dynamic state. Subjective evaluation indicated that the right buttocks and the lower back (lumbar)experience the highest discomfort for both types of seats.The type of seat found to contribute to the value of different pressure. Thus, it can be concluded that appropriate seat selection can reduce pressure as well as discomfort

A Study on Common Risks and Body Parts Complaints by Standing Workstation Female Operators in an Electronics Product Manufacturing Company

Ergonomics have improved the scope on safety and minimize risk at workplace by looking into possible factors effecting product quality, work performance and machine efficiency. The main objectives of this study are to assess, identify risks and body parts that received high number of complaints with respect to standing workstation. The methodology use in this study includes anthropometric data measurements of 146 female Malaysian operators, standing risk assessment and body parts symptoms survey form. Anthropometric data measurement results in company X showed the current standing workstation match with the female operators working height and workspace. The common risks identified for standing work are awkward posture, contact stress, wrist, static posture, fatigue, twisting of the spine, bending, too far and not reachable. Three body parts (i.e. shoulder, ankle/feet and neck) received 53% of total complaints in terms of pain and un-comfortableness. Therefore, the authors strongly recommended company X top management to find the solution to this pain and un-comfortableness complaint

Development of an Effective Cost Management Method for Malaysian SMEs

Cost management is essential to manufacturing company for sustaining market share, competitive position and profit growth. In the past, many SMEs had made mistakes during their cost management process. Two of these major mistakes were due to lack of knowledge in cost management and not knowing the right technique to use for monitoring all production costs. This paper has two main objectives: first, to present a case study on cost management method at a local SME; and secondly, to point out their mistakes and weaknesses of its cost management system. Later, the authors will present a case study of an effective cost management method practiced by a Japanese multinational company. Based on the findings of both case studies, the authors shall propose an effective costing management method that may be applicable to local SMEs for monitoring their production costs. The authors believed this costing management method will be able to help local SMEs to improve their cost management system, which eventually giving them the opportunity to achieve more profitable sales and sustainable competitive position in global market place

Setup Time Reduction in an Automotive Battery Assembly Line

One of the most critical challenges faced by many manufacturing industries is to produce high quality products using cost-efficient methods and tools in the shortest possible time and at the lowest operating costs. Many past researches had shown that in order to reduce setup time and manufacturing costs it need for fast setups and changeovers. Single Minute Exchange of Die (SMED) is one of the Lean Manufacturing System (LMS) tools used to measure setup and changeover efficiency. Setup time reduction is an important key parameter for improving manufacturing flexibility and reducing manufacturing costs. The three main objectives of this study are: first, to reduce machine setup time by 35% during a mould changeover; second, to identify the root causes of the bottlenecks operations; third, to propose and implement possible solutions to the bottleneck problems. SMED methods were applied at two major bottlenecks during setup operations, they are cast on strap and heat seal. Results and findings on the data analysis of the two bottlenecks before and after implementation of SMED are examined and analyzed. The setup operations performance is measured based on data analysis result with respect to machine setup time reduction. The result of this study shows significant reduction of cast on strap setup time to 54% and heat seal setup time to 47%. In other words, this study has achieved more than 35% of setup time reduction

Conceptual design of semi-automatic wheelbarrow to overcome ergonomics problems among palm oil plantation workers

An ergonomics problem is one of the main issues faced by palm oil plantation workers especially during harvesting and collecting of fresh fruit bunches (FFB).Intensive manual handling and labor activities involved have been associated with high prevalence of musculoskeletal disorders (MSDs) among palm oil plantation workers.New and safe technology on machines and equipment in palm oil plantation are very important in order to help workers reduce risks and injuries while working. The aim of this research is to improve the design of a wheelbarrow, which is suitable for workers and a small size oil palm plantation.The wheelbarrow design was drawn using CATIA ergonomic features. The characteristic of ergonomics assessment is performed by comparing the existing design of wheelbarrow. Conceptual design was developed based on the problems that have been reported by workers. From the analysis of the problem, finally have resulting concept design the ergonomic quality of semi-automatic wheelbarrow with safe and suitable used for palm oil plantation workers

Investigation of oil palm harvesting tools design and technique on work-related musculoskeletal disorders of the upper body

The oil palm industry is one of the important sectors in Malaysia. The growth and development of this industry shows that Malaysia is the world second-largest oil palm producers. However, in the fresh fruit bunch (FFB) harvesting process, the harvesters are exposed to many types of work-related musculoskeletal disorders (WMSDs). The FFB harvesters tend to develop WMSDs especially the shoulders and trunk. Hence, it is important to identify the exposure levels, awkward postures and the reaction forces of muscle activity based on the posture and movement of the harvesters when using pole, chisel and loading spike during the harvesting process. The objective of this study was to investigate the effect of the design of oil palm FFB harvesting tools on WMSDs of the upper body. Rapid Upper Limb Analysis (RULA) was used to investigate and assess the exposure level on the harvester body during the harvesting process. The assessment showed that the shoulders and trunk have high exposure level and undergo awkward posture. Human Musculoskeletal Model Analysis (HMMA) was used to identify the reaction force exerted on the muscle during the FFB harvesting process. In this study, 4 muscles were analysed including Triceps, Biceps, Erector Spinae and Psoas Major. The highest reaction force of 16.36 N was found on the left triceps when handling a loading spike. In conclusion, it is important to address the risks by reviewing all possible aspects that contribute to the WMSDs and interventions on the tool design, task and working shifts may be required

THE TAGUCHI APPROACH IN OPTIMIZING ENVIRONMENTAL FACTORS AFFECTING PRODUCTIVITY IN THE AUTOMOTIVE INDUSTRY

The objective of this study is to determine the dominance effects of environmental factors such as illuminance, humidity and WBGT on operators’ productivity in the Malaysian automotive industry. A case study was carried out at an automotive components assembly factory. The environmental factors examined were the illuminance (lux), humidity and WBGT of the surrounding workstation area. Two sets of representative data including the illuminance, humidity and WBGT level and production rate were collected during the study. The production rate data were collected through observations and survey questionnaires while the illuminance level was measured using photometer model RS 180-7133, and the humidity and WBGT level were measured by using Quest Temp apparatus and humidity. The Taguchi method was utilized to find the sequence of dominant factors that contributed to the productivity of the operator at that specified production workstation. The study reveals that the dominant factor that contributed to the productivity was humidity, followed by illuminance and WBGT

Assessment of Oil Palm Fresh Fruit Bunches Harvesters Working Postures Using Reba," in Advanced Engineering Forum

Abstract Ergonomics has plays an important role to improve occupational health and work productivity in most industries in Malaysia including agriculture. However, most of the workers in Malaysia especially in oil palm plantation do not highlight ergonomics awareness as priority for their safety and health. They still using manual tools and consequently exposed to ergonomics risk factors. The objective of this study is to evaluate working postures during harvesting oil palm fresh fruit bunches. The Rapid Entire Body Assessment (REBA) is used to evaluate risks working postures and movements corresponding to the tasks. From the analysis, it is revealed that most of the oil palm workers were affected by musculoskeletal disorders especially on left and right hand side. Immediate action such as conduct ergonomics training for the workers must be taken to solve this ergonomic problem

Effects of payment method on work control, work risk and work-related musculoskeletal health among sewing machine operators

Effects of payment method on work control, work risk and work-related musculoskeletal health among sewing machine operators R. Nawawi1, B.M. Deros1*, D.D.I. Daruis2, A. Ramli3, R.M. Zein4 and L.H. Joseph3 1Dept. of Mechanical and Materials Engineering Faculty of Engineering & Built Environment Universiti Kebangsaan Malaysia, Malaysia *Email: [email protected] 2Faculty of Engineering, Universiti Pertahanan Nasional Malaysia, Malaysia 3Department of Physiotherapy Faculty of Science, Lincoln University College, Malaysia 4Department of Consultation, Research & Development, National Institute of Occupational Safety and Health (NIOSH), Malaysia ABSTRACT This study aimed to identify payment method and its effects on work control, work risk and work-related musculoskeletal health among Malaysian sewing machine operators. The study sample comprised 337 sewing machine operators (male, n=122, female, n=215; aged between 18-54 years old; mean 30.74±8.44) from four different garment-making companies in Malaysia. They were being paid via time rate wages (n=246) and piece rate wages (n=91). Data was collected through Nordic Musculoskeletal Questionnaire and pen-and-paper assessment via Rapid Upper Limb Assessment (RULA). From the study, the piece rate wage group was found to take fewer breaks, had high work production demands, worked at a faster pace and experienced more exhaustion and pressure due to increasing work demands as compared to the time rate group. They were also observed working with higher physical exposure such as repetitive tasks, awkward static postures, awkward grips and hand movements, pulling, lifting and pushing as compared to those in the time rate wage group. The final RULA scores was also higher from the piece rate wage group (72.53% RULA score 7) which indicated higher work risks among them. The study found that the type of wage payment was significantly associated with work risks (p=0.036, df=1) and WRMSD at the shoulder, lower back, forearm, and leg (p<0.005, df=1). The musculoskeletal pain in these regions were reported more often by the piece rate wage group than the time rate wage group (At shoulder; OR = 2.94 with 95% confidence interval (CI): 1.39-6.20, at lower back OR = 3.16 with 95% CI: 1.74-5.74, at forearm OR = 2.55 with 95% CI: 1.56-4.17, at hip OR = 2.49 with 95% CI: 1.52-4.07 and at leg OR = 2.97 with 95% CI: 1.72-5.15). It can be concluded that the type of wage system could be one of the contributory factors in a high prevalence of WRMSD and high ergonomic physical work risks among sewing machine operators. It is recommended that sewing machine operators are better off being paid via a time rate wage system compared to a piece rate wage system to reduce work risks and WRMSD among them