Workload Analysis by Using Nordic Body Map, Borg RPE and NIOSH Manual Lifting Equation Analyses: a Case Study in Sheet Metal Industry

Abstract

The purposes of this research were to identify the lifting complaints experienced by the painting operators in the sheet metal industry at west java, Indonesia. The lifting issues such as operators’ lifting effort and risk were evaluated by combining the Nordic Body Map, the Borg Rating of Perceived Exertion and the NIOSH manual lifting equation tool. Specifically, two questionnaires that consist of Nordic Body Map and Borg Rating of Perceived Exertion and field observation were used as the research methodologies to evaluate respondents’ lifting process when loading the panel box, where its body part, door part and base plate were examined. All of the 44 full-time operators in the painting department of the sheet metal company participated in this study. Their age ranged from 20 to 40 years old. Five complaints were identified by Nordic Body Map questionnaire. These complaints were pain, discomfort, and tingling at operators’ neck, shoulders, and hips. Finding from Borg Rating of Perceived Exertion questionnaire revealed that the effort needed to lift the panel body parts were substantially higher than door parts and base plate. A new manual conveyor was then installed and the study’s recommendations were proven to be successful by reducing the 1991 NIOSH lifting index value from 1.65 to 0.91 when lifting panel body part, from 1.3 to 0.72 when lifting panel door part, and from 0.93 to 0.51 when lifting panel base plate. The value of the Borg Rating was also decreased from 13.79 to 11.96 for panel body part, from 9.36 to 8.82 for panel door part, and from 8.82 to 8.25 for panel base plate, and the lifting complaints of the painting operators were reduced.