PELAKSANAAN PENGGUNAAN RUBRIK PROJEK ILMIAH PROGRAM SARJANA MUDA KEJURUTERAAN MEKANIK DAN PEMBUATAN

PELAKSANAAN PENGGUNAAN RUBRIK PROJEK ILMIAH PROGRAM SARJANA MUDA KEJURUTERAAN MEKANIK DAN PEMBUATAN

Jaharah A. Ghani, Baba Md Deros, Jaafar Sahari and Ahmad Kamal Ariffin Mohd. Ihsan

Abstrak: Projek Ilmiah merupakan satu kursus yang sangat sukar untuk dinilai secara adil. Ini disebabkan oleh penyelia yang terdiri daripada pensyarah–pensyarah yang kebiasaannya mempunyai pemahaman dan harapan serta jangkaan yang berbeza-beza sebagai seorang insan. Oleh itu, bagi mengurangkan masalah ini satu kaedah penilaian menggunakan rubrik telah diperkenalkan. Kajian mendapati bagi tujuan penilaian Projek I, semua pensyarah telah memberikan markah kepada pelajar di bawah penyeliaan mereka seperti dalam borang pemarkahan yang disediakan. Sementara bagi tujuan penilaian Projek II, bagi pelajar kursus KP4923, pensyarah telah menilai mengikut rubrik yang disediakan. Walaubagaimanpun, bagi kursus KJ4023, hampir 40% penialaian markah mereka tidak berdasarkan rubrik yang telah disediakan.

Kata Kunci: rubrik, projek ilmiah, penyelia, penilaian, markah.

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PENILAIAN OBJEKTIF DAN HASIL PROGRAM PENDIDIKAN BERASASKAN HASIL (OBE): SOAL SELIDIK MAJIKAN INDUSTRI DAN ALUMNI

PENILAIAN OBJEKTIF DAN HASIL PROGRAM PENDIDIKAN BERASASKAN HASIL (OBE): SOAL SELIDIK MAJIKAN INDUSTRI DAN ALUMNI

Shahrir Abdullah, Norhamidi Muhamad, Riza Atiq Abdullah O.K. Rahmat, Baba Md. Deros, Noorhisham Tan Kofli, Mardina Abdullah, Mazlan Mohd. Tahir dan Andanastuti Muchtar 

Abstrak: Konsep pengajaran Pendidikan Berasaskan Hasil (OBE) mula diamalkan di Fakulti Kejuruteraan UKM bermula tahun 2005. Melalui pendekatan ini, setiap program perlu menggubal objektif pendidikan program dan hasil program setelah mengambil kira input daripada pihak berkepentingan seperti kerajaan, majikan, dan alumni. Justeru, kertas kerja ini membentangkan kaedah yang digunakan untuk mengukur persepsi kepentingan serta pencapaian penyataan-penyataan objektif pendidikan program (PEO) dan hasil program (PO) bagi program-program kejuruteraan yang ditawarkan. Dalam kaedah ini, setiap penyataan dikenal pasti ciri-ciri yang membentuknya dan dinilai mengikut skala Likert 1-5. Kaji selidik ini dihantar kepada industri dan alumni yang ada dalam pangkalan data Latihan Industri dan Alumni Fakulti Kejuruteraan dan soalan yang ditanya berkisar kepada paras signifikan penyataan tersebut atau pencapaian para graduan dan alumni. Keputusan kaji selidik ini dibentangkan berdasarkan input tersebut.

Kata kunci: pendidikan berasaskan hasil (OBE), objektif pendidikan program (PEO), hasil program (PO), soal selidik.

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KAJIAN KES PERLAKSANAAN PROSES KAWALAN STATISTIK (SPC) DI INDUSTRI PEMBUATAN MALAYSIA: PERMASALAHAN DALAM PERISIAN SPC

KAJIAN KES PERLAKSANAAN PROSES KAWALAN STATISTIK (SPC) DI INDUSTRI PEMBUATAN MALAYSIA: PERMASALAHAN DALAM PERISIAN SPC

Rosmaizura Mohd Zain, Mohd Nizam Ab Rahman, Zulkifli Mohd Nopiah, Jaharah A Ghani, Baba Md Deros, Nurhamidi Mohamad and Ahmad Rasdan Ismail

Abstrak: Proses Kawalan Statistik atau Statistical Process Control (SPC) merupakan satu teknik penting dalam kawalan kualiti. Penggunaan kaedah berstatistik ini ternyata dapat mengawal proses pengeluaran serta meningkatkan kualiti produk. Artikel ini menerangkan tentang kajian kes perlaksanaan SPC yang dijalankan di industri pembuatan Malaysia. Kajian ini memfokuskan kepada permasalahan dalam perlaksanaan perisian khusus SPC serta penglibatan pihak syarikat dalam mengendalikan aktiviti ini.  Kajian ini dilaksanakan melalui kaedah temuramah serta soal selidik ke atas perwakilan dari setiap syarikat, dan kaedah pemerhatian persekitaran syarikat. Hasil kajian ini didapati bahawa terdapat kelemahan atau permasalahan dalam perlaksanaan SPC di industri pembuatan. Antara permasalahan yang telah dikenalpasti adalah fungsi perisian SPC yang kurang efektif seperti tidak dapat memaparkan nilai data pada masa sebenar (real time data), dan mempunyai fungsi statistik yang terhad, contohnya tidak menyokong pembinaan carta kawalan sifat.  Selain itu, kelalaian dalam mengambil bacaan dan kesilapan memasukkan nilai data oleh pekerja adalah merupakan permasalahan yang terlibat dalam perlaksanaan SPC. Walaupun SPC yang diaplikasi di industri pembuatan adalah terdiri dari pakej perisian yang berbeza, namun ia dapat menawarkan fungsi terbina statistik yang berguna. SPC merupakan satu teknik yang mudah, tetapi implementasi dalam organisasi begitu kompleks kerana ia melibatkan sokongan dari beberapa faktor utama seperti penglibatan pihak pengurusan yang sepenuhnya, memberi latihan dan pendidikan SPC kepada pekerja dan meningkatkan komunikasi yang berkesan di antara pihak pengurusan dan operator.  

Kata kunci: Kualiti, Proses Kawalan Statistik (SPC), Pengurusan Kualiti secara menyeluruh (TQM), kajian kes.

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FUNDAMENTAL SITTING ANTHROPOMETRIC AND DIFFERENCES AMONG MALAYSIAN MALAYS, CHINESE AND INDIANS

FUNDAMENTAL SITTING ANTHROPOMETRIC AND DIFFERENCES AMONG MALAYSIAN MALAYS, CHINESE AND INDIANS

Md Deros,B., Daruis, D.D.I. and Mohd Nor, M.J.

Abstract: In ergonomic point of view anthropometric data is very important in product design and other applications. Hence, it is important that the data is representative of the target user or consumer of a product being designed. Few individual efforts has taken place in Malaysia in order to establish an anthropometry database that could be use to represent the Malaysian population. This is an addition to those efforts where each main race of Malaysian namely the Malays, Chinese and Indian has been measured. The measurement comprised of 16 dimensions, using traditional measuring tools. In this paper, 226 subjects were analyzed. Focus is given to seat design requirements such as sitting shoulder height for seatback lateral support, buttock to popliteal length for thigh support and sitting hip breadth for cushion width. There are significant differences between some body parts among the three races particularly in stature the proportion of the upper body part and the lower body part, which are highly correlated to body height. 

Keywords: Malaysian anthropometric, seat design, ethnic difference, stature, sitting.

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PEMBANGUNAN PANGKALAN DATA ANTROPOMETRIK UNTUK RAKYAT MALAYSIA

PEMBANGUNAN PANGKALAN DATA ANTROPOMETRIK UNTUK RAKYAT MALAYSIA

Darliana Mohamad, Baba Md Deros dan Ahmad Rasdan Ismail

Abstrak: Data antropometri untuk sesuatu populasi adalah amat penting bagi proses rekabentuk dan pembuatan sesuatu produk atau tempat kerja. Walaupun kepentingan data antropometri dapat dilihat dengan jelas namun sehinga kini masih belum terdapat pangkalan data antropometri  yang dibangunkan bagi mewakili populasi rakyat Malaysia. Kertas kerja ini membentangkan mengenai keputusan kajian data antropometri yang telah dijalankan ke atas rakyat Malaysia. Tujuan kajian pengumpulan data ini dilakukan adalah untuk membangunkan satu pangkalan data statik untuk rakyat Malaysia bagi memudahkan suatu rekabentuk dan pembinaan kemudahan diwujudkan. Seramai 408 individu diukur yang terdiri daripada 193 lelaki dan 215 wanita. Sebanyak 18 data antropometri dikumpul bagi setiap individu. Data dikumpul menggunakan cara pengukuran manual iaitu dengan pita pengukur dan pembaris. Penulis percaya data yang dikumpulkan ini dapat mewakili ukuran badan rakyat Malaysia secara umum.  

Kata kunci: Antropometrik, Ergonomik, Malaysia

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PRACTICAL APPLICATION OF BENCHMARKING TECHNIQUE IN SEMICONDUCTOR COMPANY

PRACTICAL APPLICATION OF BENCHMARKING TECHNIQUE IN SEMICONDUCTOR COMPANY

Tan Jun, Baba Md Deros and Mohd Nizam Ab Rahman

Abstract: This paper presents the practical application of benchmarking technique in Semiconductor Company. It begins with the literature review of benchmarking implementation. A study is carried out to understand the relationship between semiconductor industry’s supply chain and benchmarking practice. This study is focus on the semiconductor companies and professional personnel in semiconductor field. From the study, the result shows that benchmarking term and activities is not very familiar in the industry personnel. However, a lot of comparison had made in data presentation. Thus, a better and easier decision could be made. Through benchmarking technique also, a clearer view will be seen to have a better understanding on internal and external strengths and weaknesses respectively.

Keywords: benchmarking, semiconductor company.

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ANALISIS OWAS DAN RULA KE ATAS OPERATOR PENGENDALIAN MANUAL DI INDUSTRI AUTOMOTIF

ANALISIS OWAS DAN RULA KE ATAS OPERATOR PENGENDALIAN MANUAL DI INDUSTRI AUTOMOTIF

A.R.Ismail, Y.M.Lee, B.M.Deros and M.N.A.Rahman

Abstrak: Work related musculoskeletal disorders (WMSDs) merupakan salah satu masalah kesihatan pekerjaan yang terbesar dalam industri. Pekerja industri mudah terdedah dalam ketidakselesaan dan kesakitan semasa bekerja dalam postur yang bermasalah (awkward posture). Selain daripada membawa masalah kesihatan pada pekerja, ia juga membawa kesan jangkamasa panjang terhadap prestasi pengeluaran. Objektif kajian ini adalah bertujuan untuk mengkaji postur kerja pekerja di industri dan mencadangkan postur optimum pada pekerja tersebut bagi meningkatkan kadar pengeluaran di industri. Projek ini dilakukan dengan menggunakan tiga kaedah iaitu soal selidik ketidakselesaan kerja, analisis postur OWAS dan RULA. Sebanyak 80 borang soal selidik ketidakselesaan kerja diedarkan kepada operator dalam industri automotif untuk mengenalpastikan tahap ketidakselesaan kerja. Analisis postur dilakukan ke atas seorang operator di industri automotif. Postur pergerakan kerja postur akan direkodkan ke dalam perisian WinOWAS dan CATIA V5 R16 dan kedua-dua analisis dijalankan masing-masing. Analisis OWAS dan RULA dapat mengenalpasti postur bermasalah (awkward posture). Melalui keputusan yang diperolehi melalui analisis, perbandingan antara soal selidik ketidakselesaan kerja, kaedah analisis postur OWAS dan RULA dilakukan dan postur yang bermasalah akan diperbaiki bagi mendapatkan postur pergerakan optimum bagi subjek. Terdapat beberapa batasan kajian yang dikenalpasti semasa kajian ini dijalankan iaitu disebabkan pengunaan hanya seorang sampel sahaja dan pengunaan anggaran sudut badan semasa merekod kerja postur ke dalam perisian. Postur optimum untuk subjek melakukan kerja bagi mengelakkan masalah ketidakselesaan dan meningkatkan tahap keselamatan dapat diperolehi melalui kajian ini.

Kata Kunci: OWAS, RULA, Postur Awkward, WinOWAS, CATIA, Ergonomik

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KAJIAN BEBANAN MELAMPAU MENGGUNAKAN KAEDAH LUBA DI KALANGAN PEKERJA PEMASANGAN INDUSTRI AUTOMOTIF DI MALAYSIA

KAJIAN BEBANAN MELAMPAU MENGGUNAKAN KAEDAH LUBA DI KALANGAN PEKERJA PEMASANGAN INDUSTRI AUTOMOTIF DI MALAYSIA

A. R. Ismail, N.M.F.Fahmi, M.R.A.Mansor and B.M.Deros

Abstrak: Kecederaan di tempat kerja yang berkaitan dengan ergonomik boleh menyebabkan majikan dan pekerja menanggung kos yang tinggi samada di persekitaran kilang mahupun di pejabat. Banyak kilang yang dibina di Malaysia tidak mempertimbangkan keadaan persekitaran kerja yang ergonomik. Ini menyebabkan prestasi perkerja terutama dari sektor pengeluaran mengalami bebanan melampau sekaligus menjejaskan prestasi pekerja terbabit. Oleh itu kajian ini dijalankan untuk mengukur tahap bebanan (excessive loading ) ke atas operator kilang terutamanya operator kilang yang melibatkan pemasangan komponen automotif di Malaysia. Dengan menggunakan analisis LUBA (loading on the upper body) bahagian-bahagian badan yang terdedah kepada bebanan melampau akan dikenalpasti. Kemudian cadangan pengubahsuaian ke atas postur bekerja dan stesen kerja terbabit akan dilakukan bagi mengurangkan kesan bebanan melampau ke atas produktiviti keluaran pekerja terbabit. Sebanyak 80 borang soal selidik yang digunakan untuk menentukan tahap ketidakselesaan telah diisi oleh operator. Hanya seorang subjek dan satu stesen kerja sahaja digunakan dalam kajian ini. Penggunaan perisian CATIA V5 R16 adalah untuk menentukan atau menganggarkan sudut postur yang dilakukan oleh subjek. Kemudian analisis LUBA digunakan untuk mengenalpasti postur yang bermasalah dan sekaligus memperbaikinya supaya mendapat postur yang optimun dan selamat. Beberapa batasan kajian telah dapat dikenalpasti iaitu hanya satu subjek sahaja yang digunakan dan sudut postur yang digunakan hanyalah anggaran yang diperolehi melalui penggunaan perisian.

Kata kunci: ergonomik, LUBA, postur.

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LEAN VIEWED AS A CULTURE

LEAN VIEWED AS A CULTURE

Norani Nordin, Baba Md Deros and Dzuraidah Abdul Wahab

Abstract: For the past few years, almost every manufacturing industry has been trying to get “lean”. However, many of these firms were not successful or faced difficulties to sustain the success in lean manufacturing. One of the reasons is misapplication of existing lean manufacturing tools that is often due to inadequate understanding of lean manufacturing concept and philosophy. The aim of this paper is to thoroughly discuss the question of “What is Lean Manufacturing?”. In order to address the elements of misconception surrounding lean manufacturing, this paper shall focus on the history, definition, philosophy and existing tools of lean manufacturing. Based on the literatures reviewed, the authors would like to propose a general theoretical framework that will be used as guidelines to the research conducted.

Keywords: lean manufacturing, culture, industry.

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Internal Benchmarking Practice in Malaysia Company

Internal Benchmarking Practice in Malaysia Company

Deros, B.M., Tan, J. and Ab Rahman, M.N.

Abstract: This paper presents the practical application of internal benchmarking technique in a semiconductor company. A qualitative study was carried out to understand about the internal benchmarking technique and its implementation process. In today’s competitive market, companies are forced to design and manufacture high quality and marketable products that are required by the customers. As such, one of the techniques used to achieve these goals is to benchmark the current product that is currently available in the market and to make it better. This internal benchmarking process includes cost effectiveness, quality improvement and process optimization. The result of the study shows internal benchmarking implementation enables the company to understand their strengths and weaknesses. It will eventually drive the company to initiate the continuous improvement activities to improve them. In addition, internal benchmarking implementation also contributes many advantages towards lean manufacturing practices and helps to achieve the company’s business goals. 

Keyword: Internal benchmarking, continuous improvement, cost effectiveness, quality.

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A LITERATURE REVIEW ON BENCHMARKING

A LITERATURE REVIEW ON BENCHMARKING

Baba Md. Deros, Masoomeh Zeinalnezhad, Mohd. Nizam Ab.Rahman and Towhid Pourrostam

Abstract: In today's highly competitive and rapidly changing global economy had forced organizations to consider and implement a wider variety of innovative management philosophies and techniques. One such technique is benchmarking which has been attracting considerable attention for its effectiveness. A large number of publications by various authors reflect the interest in this technique. In the pass, many reviews of literature on benchmarking have been done by many authors. However, considering the contributions in the recent times, the authors had attempted to conduct a more comprehensive review with respect to bench marking technique. In this paper, the authors had reviewed the benchmarking literature in a way that would help researchers, academicians and practitioners to take a closer look at the growth, development and applicability of this technique. There are about 450 articles on the benchmarking topic were published in the last 10 years, as revealed in this literature review. Considering the number of publications it can be said that the benchmarking technique has seen a steady growth and appears to be heading towards maturity level.

Keywords:  Benchmarking, classification, competitive, technique, effectiveness.

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MUSCULOSKELETAL DISORDERS AND JOB SATISFACTION AMONG OPERATORS IN AUTOMOTIVE ASSEMBLY JOBS

MUSCULOSKELETAL DISORDERS AND JOB SATISFACTION AMONG OPERATORS IN AUTOMOTIVE ASSEMBLY JOBS

Mohd Hanifiah Mohd. Haniff , Ahmad Rasdan Ismail and Baba Md. Deros

Abstract: Assembly processes occupy an important position in the automotive industry. Research has explored the association of psychosocial and work organization factors such as job satisfaction and work stress with both lower and upper extremity musculoskeletal disorders. Thus, this study aims to examine the discomfort level base on ergonomics factors and to determine discomfort distribution body relating with the task made. In addition, this study carried out to analyze a core factor that contribute to the worker productivity in determining the features interaction among comfort level, environmental factors (noise, temperatures and evidence light) and workstation dimension. Two hundred and ten samples of operators were derived from five automotive manufacturing companies to identify the dominant factors. This study will be carried out using questionnaire in those factories and data gathered will be analyzed using SPSS software. In the data analysis, research showed that the left shoulder is part of the body most involved in a lot of activity like lifting, pulling, twisting, carrying and holding. Apart from that, majority of respondents reported that their works are exposed to a high level of noise and it was a dominant factor associated with productivity. Improvement must be made and companies must have a particularly important role in establishing a balance between job satisfaction and working methods, and the protection of employees' health, safety and other interests.

Keywords: Musculoskeletal disorders, job satisfaction, automotive industry, assembly work, environmental factors.

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INTRODUCTION OF NEW PRODUCT COMPETITIVE CAPABILITIES, TOOLS AND TECHNIQUES

INTRODUCTION OF NEW PRODUCT COMPETITIVE CAPABILITIES, TOOLS AND TECHNIQUES

Nor Hidayah Abu, Baba Md. Deros and Norani Nordin

Abstract: Competitive Capabilities is very crucial in new product development to sustain market competitiveness. It also influences a firm’s performance. In order to avoid failure in new product development, top management needs to assign product with greater competitive advantage at the very early stage of product design and development activities. Product competitive advantage provides strength of a firm’s ability to meet customer needs, good quality performance and design, at the right time, suitable price, and flexible to uncertainty change. In addition right tools and techniques should be implemented in the firm to ensure the product are better, cheaper and takes shorter time from idea conception to market place. The tools and techniques used in developing the new product must utilise the latest (up-to-date) technology.

Keywords: Quality tool, product development.

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Postural Angle Measurement: Manual vs. Picture Recognition Software

Postural Angle Measurement: Manual vs. Picture Recognition Software

Darliana Mohamad, Baba Md Deros, Ahmad Rasdan Ismail, Dian Darina Indah Daruis and Slamet Riyadi

Abstract: At present, there are vast selections of ergonomics measurement tools that have been developed for tasks, equipments and environments analysis. The measurement method for ergonomic assessment is done either by traditional or modern methods. This paper presents a comparative study of two different methods for measuring postural angles of driver’s posture. The first method is manual measurement and the second method is using picture recognition software. The main objective of this study is to validate a new measurement method using the picture recognition software. A simple experiment was conducted in order to gather the required data. During the experiment each subject is required to sit on the driver’s seat in their preferred comfortable driving postures. Angles measurement is then taken after five minutes the subject has been in the sitting position to allow him/her adapt with the seat environment and fabrics. Later, postural angle of the subject’s is measured using angle measurement kits and at the same time picture of subjects on the set is also taken. Results from both methods shows that the new measurement method using the picture recognition software was reliable and could avoid the hassle by reducing time and effort in

the measurement process.

Keywords:  Ergonomic, postural angle, comfort, car seat, Mann-Whitney U test.

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THE BASIC OF BENCHMARKING

THE BASIC OF BENCHMARKING

Baba Md. Deros, Norashikin Rahman and Mohd. Nizam Abdul Rahman

Abstract: The main objective of this paper is to understand the basic of benchmarking technique. It discusses the relationship between quality, TQM and benchmarking, different views of definitions and benchmarking types, evolution of modern benchmarking as well as the advantages of the implementation. Previous studies showed that benchmarking adoption could help the companies to get higher profit and improve their performance. Since benchmarking is a great improvement tool, companies which involved comprehensively in benchmarking implementation would achieve significance benefits than others.

Keywords: Benchmarking, total quality management (TQM), quality

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Application of Malaysian Anthropometric Data in Home Furniture Design

Application of Malaysian Anthropometric Data in Home Furniture Design

Baba Md Deros, Darliana Mohamad, Ahmad Rasdan Ismail and Muhammad Nazeer Muhammad Nazree

Abstract: The objective of this paper is to present the design of home furniture that incorporates the Malaysian anthropometric data. In this study, anthropometric data of 1007 Malaysian respondents’ physical body parts were measured manually using an anthropometer and recorded. It is assumed that the 1007 respondents represent the overall Malaysian population. The collected data were later analysed to determine the: mean, standard deviation, 5th and 95th percentile values of the respondents. Having done that the authors then starts designing the home furniture by using the AutoCAD software. In conclusion, the home furniture designed using Malaysian anthropometrics data would fit, appropriate, comfortable to at least 90% of the Malaysian population with respect to ergonomics, helps to reduce the risks of injuries and pains among Malaysian home furniture users.   

Keywords: home furniture, anthropometric data, Malaysian, ergonomics, respondents.

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DESIGN OF AN ANTHROPOMETRIC MEASUREMENT CHAIR PROTOTYPE

DESIGN OF AN  ANTHROPOMETRIC MEASUREMENT CHAIR PROTOTYPE

Baba Md. Deros, Chia Swee Yoon, Darliana Mohamad and Ahmad Rasdan Ismail

Abstract: Anthropometry plays an important role in ergonomics and product design. Currently, there are various standardized measurement equipments to measure the human body dimensions available in the market. However, these measurement equipments have to be used separately for measuring different dimensions of the human body. In this study, the authors had designed a prototype of anthropometric measurement chair, which could be used to measure 20 anthropometric data both in sitting and standing positions. This prototype that is easy to use can measure the body dimensions of female and male adults. In addition, an analysis on the design of anthropometric measurement model chair prototype was also done. To design this anthropometric measurement chair, the development steps began with the preliminary study and literature review.  During the conceptual design phase, the authors had generated many concepts with respect to the design of anthropometric chair.  After making critical comparisons and analysis, the authors finally selected the most practical design for the anthropometric chair.  Having done that, the authors then determined the final design and dimension of key features for the prototype. Later, it was followed by the detailed design and design analysis with respect to the prototype.  

Keywords: Anthropometry, ergonomics, anthropometric chair.

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DETERMINATION OF OIL PALM PROCESSING ACTIVITIES FOR BENCHMARKING

DETERMINATION OF OIL PALM PROCESSING ACTIVITIES FOR BENCHMARKING

Fatimah Mahmud, Baba Md Deros and Dzuraidah Abdul Wahab

Abstract: Currently, Malaysia is the largest producer and exporter of oil palm. Nevertheless, Malaysia may soon lose its position if there are lacks of initiatives to sustain it. Therefore, this paper aims to introduce the use of benchmarking steps in oil palm processing activities with specific review on various factors influencing the oil palm yield production. With this effort, it will drives the improvement in the oil palm yields; both Fresh Fruit Bunches (FFB) and the Crude Palm Oil (CPO) extraction.

Keywords: Benchmarking, oil palm processing industry, influential factor

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A REVIEW ON LEAN MANUFACTURING PRACTICES IN SMALL AND MEDIUM ENTERPRISES

A REVIEW ON LEAN MANUFACTURING PRACTICES IN SMALL AND MEDIUM ENTERPRISES

Ahmad Nasser Mohd. Rose, Baba Md. Deros and Mohd. Nizam Abdul Rahman

Abstract: The literature studies showed lean manufacturing started at Toyota car manufacturing plant, Japan, which is known as Toyota Production System (TPS). The main pillars in TPS are Just in time and automation which main objective is to identify and eliminate waste in an organization.  Lean manufacturing can be applied successfully in all industries providing a full understanding on lean ingredients i.e. concept, principles and practices. There are numerous practices being highlighted by academicians and practitioners which are compulsory to be implemented in order to gain full benefits of lean.  As small and medium enterprises (SMEs) are resources constraints, facing difficulties to adopt all lean principles. To compete in global competitive marketplace, the SMEs have to strive for world class performance through implementation of lean manufacturing. The main objective of this paper is to carry out a critical review on the lean manufacturing practices. Previous studies showed total lean manufacturing practices could help manufacturing organization to gain full benefits i.e. reduction in inventory, lead time, set up time, and etc., provided they’re adopting all practices. As the resources constraint to SMEs, the selected practices should be feasible to the company problem and low investment.

Keywords: Lean manufacturing, TPS, Small and Medium Enterprises (SME)

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PREVALENCE OF MUSCULOSKELETAL DISORDERS DUE TO MANUAL MATERIAL HANDLING AMONG WORKERS IN AN AUTOMOTIVE MANUFACTURING PLANT IN MALAYSIA

PREVALENCE OF MUSCULOSKELETAL DISORDERS DUE TO MANUAL MATERIAL HANDLING AMONG WORKERS IN AN AUTOMOTIVE MANUFACTURING PLANT IN MALAYSIA

Baba Md. Deros, Dian Darina Indah Daruis and Sawal, N.A.

Abstract: A cross sectional study was carried out among workers at an automotive manufacturing plant in Malaysia. The study has two major objectives: first, to determine the prevalence of musculoskeletal disorders (MSD) among workers who perform the manual material handling (MMH) task; and second, to determine the ergonomics risk of MMH at selected workstations. For the first objective, respondents were selected through random sampling. Then, a body parts symptoms survey (BPSS) data sheets were given to the respondents to obtain the prevalence of MSD among these workers. For the second objective, respondents were selected based on the in-house clinic (IHC) visitations data. Results from 500 respondents showed that the highest prevalence of MSD was low back pain (LBP). It was found from interviews of 17 workers who had 3 or more visitation times to the IHC that the main reason of the ergonomic risk comes from the task that they perform.

Keywords: Malaysian automotive, musculoskeletal disorders, prevalence, manual material handling, back pain.

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A study on Noise Exposure and Its Effects on Employees’ Health, Safety and Productivity in Plastic Based Industry

A study on Noise Exposure and Its Effects on Employees’ Health, Safety and Productivity in Plastic Based Industry

B. M. Deros, M.H.M. Haniff, D. Mohamad, T. J. Yee and A. R. Ismail

Abstract: The objective of this paper is to present a study on noise exposure and its effects on employees’ health, safety and influence to their productivity performance. In this study noise levels were measured at several work locations to determine whether there noise problems or not. Employees may suffer permanent hearing loss due over exposure to high noise level. Therefore, noise level measurement is an important activity at workplace to preserve employees hearing capability and implementing noise control procedure. Sound level meter and noise dosimeter were used for measuring noise level and noise dose at the designated work locations. The study was carried out at three different plants in plastics based industry. The results of the study shows all the work location in the three plants are within the allowable levels according to the First Schedule of Factories and Machinery (Noise Exposure) Regulations 1989, which falls under the Factories and Machinery Act. 5. In essence, the authors could conclude that workers working in plastic based industry in Malaysia are not over exposed to high noise levels beyond the permissible limits as required by law.

Keywords: Noise, exposure, effects, health, safety.

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THE INFLUENCE OF SOUND PRESSURE LEVEL TOWARDS WORKERS’ PRODUCTION RATE

THE INFLUENCE OF SOUND PRESSURE LEVEL TOWARDS WORKERS’ PRODUCTION RATE

A. R. Ismail, M. H. M.Haniff, B. M.Deros, M. N. A. Rahman, M. Z. Nuawi and M. R. A. Rani

Abstract: The aim of the study was to determine the effects of noise on the operators’ productivity and performance at Malaysian automotive industry. One automotive assembly factory had been chosen as a subject for the study. The subjects were workers at the assembly section of the factory. The environment examined was the sound pressure level (dBA) of the surrounding workstation area. One set of representative data, which is the sound pressure level (dBA) and production rate were collected during the study. The production rate data were collected through observations and survey questionnaires while the sound pressure level (dBA) was measured using Quest Hand Held Pro Sound Level Meter. The correlation and linear regression analysis were conducted in order to obtain the relationship between the effects of sound pressure level (dBA) to the worker productivity and performance. The results from the correlation analysis revealed there is a weak negative relationship between the sound pressure level (dBA) and the productivity of the workers. The linear regression analysis further reveals that there is a linear equation model with negative slope to describe the relationship of sound pressure level (dBA) and workers productivity for the assembly section involved.

Keywords: Sound Pressure Level, Productivity, Automotive Industry.

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OPTIMIZING NOISE LEVEL TO ENHANCE INDUSTRIAL WORKERS PERFORMANCE USING ARTIFICIAL NEURAL NETWORK

OPTIMIZING NOISE LEVEL TO ENHANCE INDUSTRIAL WORKERS PERFORMANCE USING ARTIFICIAL NEURAL NETWORK

A. R. Ismail, M. Y. M Yusof, B. M. Deros, M. M. Noor and K. Kaardigama

Abstract: Noise is one of the environmental factors that contribute significant effect on the worker performance in automotive industries. This paper presents an optimization of noise level towards the worker productivity rate at one of the Malaysian industry. An assembly automotive manufacturing industry was chosen to conduct the study by observing and measuring the noise level and worker’s productivity rate. The data then were analyzed by using Artificial Neural Network (ANN) analysis and it is commonly used to analyze and obtain the best linear relationship from the collected data. It is apparent that from the linear relationship obtained, the optimum value of production (value≈1) is attained when the noise level is 81.62 dBA. The optimum value production rate (value≈1) for one manual production line in that particular company is successfully achieved. Using ANN analysis, the optimum environmental factor managed to be predicted.

Keywords: Artificial Neural Network (ANN), Optimum, Productivity, Noise, Environmental.

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CORRELATION BETWEEN HUMAN ANTHROPOMETRIC DATA AND COMFORTABLE DRIVING POSTURAL ANGLES

CORRELATION BETWEEN HUMAN ANTHROPOMETRIC DATA AND COMFORTABLE DRIVING POSTURAL ANGLES

Darliana Mohamad, Baba Md Deros, Ahmad Rasdan Ismail and Dian Darina Indah Daruis

Abstract: Drivers fatigue is always associated with road accidents and fatalities. In general, fatigue is a result of long driving duration and static posture. Therefore, in designing a car driver’s seat, it is important to ensure a comfortable driving posture. In addition, presently car buyers have the preference to buy cars that incorporates safe and comfortable features. The main objective of this paper is to discuss the relationship between anthropometric data and comfortable driving postural angles. Forty five participants were involved in this study, which comprise of 19 females and 26 males. Both anthropometric data and postural angles measurement was measured and recorded by using photographic technique and analysed by using a software. During the experiment, each participant was required to sit on the driver’s seat in his or her preferred comfortable driving postures. Images of the participant’s driving posture was taken after five minutes he or she has been in the driving position to allow him/her adapt with the seat environment and fabrics. In order to get high level of data accuracy and reliability, body joints will be marked with sticker markers. Prior to that, 10 anthropometric data of each participant was measured and recorded. The anthropometric and the comfortable driving postural angles were analysed statistically with Pearson correlation using the SPSS software. The correlation relationship result showed that low positive correlation between the stature and elbow angle (correlation coefficient 0.398, p<0.01). Meanwhile, there are three relationships that show low negative correlation for the shoulder to elbow length; between the trunk-thigh angle (correlation coefficient -0.311, p<0.05) and the knee angle (correlation coefficient -0.298, p<0.05); and also between the elbow to grip length and the trunk-thigh angle (correlation coefficient -0.327, p<0.05). The experimental result shows that there is a correlation between the human body anthropometric data and the comfortable driving posture angles.

Keywords: Pearson correlation, anthropometric, driving postural angles, seat comfort.

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DEVELOPMENT OF A MALAYSIAN ANTHROPOMETRIC DATABASE

DEVELOPMENT OF A MALAYSIAN ANTHROPOMETRIC DATABASE

Darliana Mohamad, Baba Md Deros, Ahmad Rasdan Ismail and Dian Darina Indah Daruis

Abstract: Human being plays an important role in the functioning of socioeconomic system such as in developing equipment, machinery, workstation, and objects. The most important criteria which have been suggested in ergonomic were the system must fit anthropometrically, comfortable and safe to use. Therefore the designer must ensure those important criteria such as the anthropometric data were applied before the system could be use by the user. Several literatures were presented in this paper to show the importance of incorporating anthropometric concern in designing processes. Eventhough the importance of anthropometric database is recognised, a published anthropometric database for Malaysian population is still not available. This paper presents a summarized data of a Malaysian population anthropometric study. The objective of the study was to develop an anthropometric database for Malaysian population. The study was conducted using anthropometric data of 1,007 Malaysian consisting of 516 males and 491 females. The equipments used in this study were measuring tools comprised of Human Body Measuring Kit and Anthropometer for body dimension measurements. A total of 40 anthropometric dimensions were measured in this study. The data collection was for both standing and sitting postures. The database comprised of the important values such as the mean and the standard deviation, the 5th and 95th percentile. The study had successfully produced a detailed and comprehensive anthropometric database for Malaysian population which can be used in the future by all designer and engineers in designing process.

Keywords: ergonomics, anthropometry, human-machine, design.

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A CONCEPTUAL FRAMEWORK FOR FRONT-END PROCESS IMPLEMENTATION FOR SMEs

A CONCEPTUAL FRAMEWORK FOR FRONT-END PROCESS IMPLEMENTATION FOR SMEs

Noor Hidayah Abu, Baba Md Deros and Dzuraidah Abd Wahab

Abstract: The purpose of this paper is to present a conceptual framework for front-end process implementation in small medium-sized enterprises (SMEs) taking into consideration their characteristics. The proposed framework described in this paper encompasses two main elements: the “foundation elements” and “general methodology”. In order to ensure success, SMEs need to fundamentally understand the implementation of NPD process within SMEs context, rather than fitting large organizational practice. Current frameworks for front-end implementation process have been developed however some of the frameworks unaware with the characteristics of SMEs which are constraint by knowledge, skills and resources (e.g.: financial, technological, human and time). The first part of this paper elaborates front-end process definition and background. The next part focuses on differences in characteristics between large organizations and SMEs with respect to front-end implementation. Later it followed by comparing and revising some existing frameworks found in the literature. The proposed conceptual framework is believed to be applicable and suitable for SMEs. SMEs are chosen because they played a major role in the development of Malaysian economy. In other words by improving SMEs business process the resultant effect on the overall Malaysian economy will be very significant.

Keywords: font-end, small to medium-sized enterprises, implementation, new product development.

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