osInternational Journal of Civil Engineering and Technology (IJCIET)
Volume 10, Issue 04, April 2019, pp. 1922-1932, Article ID: IJCIET_10_04_201
Available online at http://www.iaeme.com/ijciet/issues.asp?JType=IJCIET&VType=10&IType=04
ISSN Print: 0976-6308 and ISSN Online: 0976-6316
© IAEME Publication
Scopus Indexed
APPLICATION OF THE REBA METHOD TO
OSH SYSTEMS TO INCREASE WORK
PRODUCTIVITY (A CASE STUDY AT PT.
EKSONINDO MPI, BANDUNG, INDONESIA)
Paulus Sukapto*, Franzeska Cynthia and Sebastian Standiklaus
Department of Industrial Engineering, Parahyangan Catholic University, Bandung, Indonesia
*Corresponding author
ABSTRACT
PT. Eksonindo MPI is a company that manufactures various kinds of bags that are
marketed with Export, Eiger and Bodypack trademarks. At present, operators who
carry out their work often complain that certain parts of their body hurt. This pain is
caused by the presence of a poor working system. Improving the work system can be
accomplished by analyzing the body posture of nine specific work activities. Analysis
of the worker’s posture employs the REBA method. The results of the REBA analysis
indicate that all nine activities carry moderate and high risks. Proposed improvements
have been made by designing table and chair sizes using the anthropometric data of
the Indonesian workers involved. The proposed improvements made at a later stage
were simulated and recalculated using the REBA score. The simulation results of
proposed improvements show a significant improvement so that it will be convenient as
a safety fund or investment for workers.
Key words: risk assessment, Rapid Entire Body Assessment, ergonomics,
anthropometry
Cite this Article: Paulus Sukapto, Franzeska Cynthia and Sebastian Standiklaus,
Application of the Reba Method to Osh Systems to Increase Work Productivity (A
Case Study at Pt. Eksonindo Mpi, Bandung, Indonesia). International Journal of Civil
Engineering and Technology, 10(04), 2019, pp. 1922-1932
http://www.iaeme.com/IJCIET/issues.asp?JType=IJCIET&VType=10&IType=04
1. INTRODUCTION
Various types of products are needed by human beings to live their daily lives, ranging from
primary, secondary, to tertiary needs. Primary needs according to [29] are basic human needs
that require each individual to meet them. Basic human needs consist of clothing (clothing),
food (food), and shelter (residence).
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Application of the Reba Method to Osh Systems to Increase Work Productivity (A Case Study at
Pt. Eksonindo Mpi, Bandung, Indonesia)
PT. Eigerindo MPI is a company that provides primary needs-related products in the form
of clothing, bags, and outdoor gear. With a broad market share, PT. Eigerindo MPI has a high
demand that must be fulfilled. PT. Eksonindo MPI is a subsidiary of PT. Eigerindo MPI whose
special function includes the production of bags for the trademarks of PT. Eigerindo namely
Eiger, Export, and and Bodypack. In its production, production operators often complain about
their work, as can be discerned in Table 1. The data concerning complaints in Table 1 are data
taken through observations made from June 28, 2018 to July 31, 2018 at PT. Eksonindo MPI.
Table 1. Recapitulation of Complaints Lodged by Workers
No Number of Body Parts Total Number (persons)
Neck
1
11
Shoulder
2
9
Back
3
45
Arms
4
33
Feet
5
14
Total
112
Complaints lodged at PT. Eksonindo MPI are based on the inconvenience felt by the
operator that has led to work-related risks [6,18]. Based on the complaints lodged by the
operators, it is necessary to improve the work system. One of the steps to be taken consists of
the application of ergonomic methods. The application of ergonomic principles will help
improve work productivity. In addition, the more important aspects to be improved are that
operators feel more comfortable and safe when carrying out their activities [1].
In several other studies, the application of ergonomic methods needs to be aware of the
operators in order to produce greater improvement [5,12,24,32] recommend that in the
implementation of ergonomics interventions with proper knowledge among workers and health
education on common postural change, implementation and monitoring of laws among
industries are recommended to reduce morbidity due to musculoskeletal disorders (MSD) [2].
MSD can be caused by poor working methods, such as working posture, repetitive and forceful
activities and static muscle load [4,15,16]. Other studies reported an association of poor body
postures with pain or symptoms of MSD [7,25].
According to [13,17] , one of the efforts is to improve the work system comprehensively
using the REBA Method [8,11,21,26], adding that REBA can significantly improve the
performance of the operator because of overall improvements [2,11,21,26].
Rapid Entire Body Assessment or REBA is a method of evaluating the worker’s body
posture at work. REBA is an appropriate method for analyzing the risk involved with the task
carried out by the operator as a whole. An overview of the measurement and analysis system
using REBA can be seen in Figure 1. Taking the value of REBA into account, the risk of
working conditions experienced by workers at PT. Eksonindo MPI can be analyzed and
formulated into a proposal for these conditions so as to reduce work risks on the production
floor.
The purpose of this research is to evaluate the work system risk for operators on the
production floors of PT. Eksonindo MPI employing the REBA method and drawing up and
submitting a proposal in the form of a work system improvement plan so that the risk of the
work system can be reduced.
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Paulus Sukapto, Franzeska Cynthia and Sebastian Standiklaus
2. METHOD
The study has been conducted to analyze the posture of workers involved in the production
process at PT. Eksonindo MPI. The study was undertaken from June 28, 2018 to July 31, 2018.
Research was conducted into nine activities that are generally carried out in the process of
manufacturing a backpack.
The data was collected by way of the REBA method, and obtained in the form of risk
assessment of the nine activities. Subsequently, the proposed improvements were made using
ergonomic principles. The proposal was submitted in the form of ergonomic tables and chairs
designed using the anthropometric data from Indonesian workers included in the age category
of 18-47, as collected in 2018. Furthermore, the assessment of posture produced by the
proposed improvements was re-analyzed using the REBA method.
Figure 1. REBA Employee Assessment Worksheet.
3. RESULTS AND DISCUSSION
The production process of manufacturing bags at the company was divided into nine activities,
as can be seen in Table 2.
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Application of the Reba Method to Osh Systems to Increase Work Productivity (A Case Study at
Pt. Eksonindo Mpi, Bandung, Indonesia)
Table 2. Sequence of Production Activities
No.
Production Activity
No.
Production Activity
No.
Production
Activity
1
Gluing
4
Sealing/Stitching in Seated
Position
7
Sealing Tape
2
Installation of Variations
5
Bag Assembly
8
3
Stitching in Standing Position
6
Bartack
9
In-Line
Inspection
Final
Inspection
Using the method of determining the REBA score referred to in Figure 1, it can be seen
that each process attains a different score.
The value of the REBA score can be categorized into several risk groups. Below follows
the recapitulation of the REBA score and the risk group.
Table 3. Recapitulation of REBA Score
No.
Process
REBA Score
Risk
1
Gluing
7
Medium Risk
2
Installation of Variations
10
High Risk
3
Stitching in Standing Position
9
High Risk
4
Sealing/Stitching in Seated Position
6
Medium Risk
5
Bag Assembly
8
High Risk
6
Bartack
8
High Risk
7
Sealing Tape
6
Medium Risk
8
In-Line Inspection
7
Medium Risk
9
Final Inspection
6
Medium Risk
The value of the REBA score in Table 3 above consists of several components of
calculation. The first component is Segment A. This segment discusses the neck, back and leg
posture of the operator. After obtaining the third value of this posture, the workload value is
added to Segment A. Each posture is evaluated by comparing the extreme posture of the
operator when doing work in body positions as depicted in the drawings in Figure 1. The
following components make up Segment B. Segment B discusses the operator's upper arm,
forearm and wrist posture. Using the same calculation method, the B posture value will be
obtained. The value attained in Segment B will be obtained when the coupling value is added
to posture B. The last segment in REBA is Segment C. This has a variable value adjusting the
values of Segment A and Segment B. The value of Segment C can be seen in table C in Figure
1.
Based on the REBA score of nine, these activities can be grouped into two categories of
risk, namely high and medium. High risk with a score of 8 to 10 is found in as many as 4 work
stations. Medium risk with a score of 6 to 8 is encountered in 5 work stations. Next, the
discussion will focus on operations that have a REBA score with only high risk groups.
Therefore, the operations to be followed up are variations, stitching in standing position, bag
assembly and bartack. In general, a high REBA score is caused by several of the same reasons.
Some of these reasons are the position of the worker's body, including the neck, torso, arms,
and legs, in a position that is not ergonomic as long as the task is carried out. In most activities,
a high REBA score is caused by workers who bow or bend down during the observed activity.
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In addition, the position of the upper arm and forearm of the worker greatly influences the
magnitude of the REBA score. In most activities, workers must raise their arms quite high or
far removed from their trunk. The position of the arm at quite a large angle from the torso
causes the score for the arm to be high. The size of the arm part or Part B score will certainly
greatly affect the REBA score from the activity.
A high REBA score for four activities, namely sewing activities carried out while standing,
variation installation activities, bartack activities, and assembly activities led to the design of a
proposed improvement. Proposed improvements are made to reduce the risk of the existing
tasks. These proposed improvements were made based on the anthropometric data of the
Indonesian workers who fall into the age group ranging from 18 to 47, as collected in 2018.
Improvements to the four operations will be carried out by by making the ideal table and chair
and also changing the work posture of the operator so that workers obtain workplaces that are
in accordance with the anthropometry of the operator [14,20,23]. In order to obtain a table and
chair size that is suitable for the operators, the design process involves workers, management,
and ergonomists [19,31]. The following is a discussion of each of these operations, and includes
suggestions and illustrations.
Table 4. Evaluation and Improvement of Activities Involving Installation of Variations
A
Stickman
Illustration of
Activities
B
Proposed Tables
C
Proposed Dimensions of
Chairs
D
Illustration
The Pairing Process Variation has an initial REBA value of 10. The proposal covers a table
and chairs. The table and chairs will be adjusted to the size of the anthropometry so that they
will have the right size for the operator. The calculation of the REBA score referring to Figure
1 produces a REBA score of 3. Below follow the details of the calculation.
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Application of the Reba Method to Osh Systems to Increase Work Productivity (A Case Study at
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Figure 2. REBA Assessment Activities for Installation of Variations
The proposed improvements given for the installation of variations are in the form of an
ideal table and chair. In the proposal given, the installation activities for variations that were
initially carried out manually will be conducted using a stamp machine already in possession
of the company. The proposed table has the same surface area as the table currently in use.The
same length and width of the table is caused by the size of the table that has been used by the
company, which cannot be changed. Therefore, the length and width of the table being used
amount to 960mm and 600mm. The height of the table used by the company measures 600mm.
As explained earlier, the ergonomic table height (taking into account popliteal height, thigh
thickness, and elbow height) is 656.5mm. The difference between the table height that has been
used and the height of the ergonomic table resulted in the design of a stage as high as 56.5mm.
The sewing table that has been used by the company will now be placed on the stage so that
the table height will be 656.5mm, according to the ergonomic table height.
The proposed chair is designed using hip width, popliteal length, and popliteal height in
anthropometric data. The width of the hip is chosen as the length of the chair because the entire
hip of the operator will come into contact with the surface of the chair. Popliteal length is
chosen for the width of the chair for the same reason, namely because the popliteal length of
the operator will come into contact with the surface of the chair when the person is seated. In
addition, popliteal height is used to design chair height. An ergonomic chair is a chair that can
accommodate hip width, popliteal length, and the worker's popliteal height. Thus, users can sit
with their feet resting on the floor and bend at a 90 degree angle when the chair is being used
with feet resting on the floor and bent at a 90 degree angle when the chair is used.
In addition to the installation process of variations, the next process to be improved is the
stitching process performed while standing.
Below follows a supporting picture for sewing operations performed while standing.
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Table 5. Evaluation and Improvement of Stitching Activities in Standing Position
A
B
C
D
Stickman
Illustration of
Activities
Proposed Tables
Proposed Dimensions of
Chairs
Illustration
The stitching process in standing position will have the same calculation method as the
variation installation process. The REBA score obtained from this particular process amounts
to 3. Proposals for improvement are also given for this stitching activity carried out while
standing. The proposed improvement for this activity is an ergonomic chair to be used together
with a table that is currently used by the company. Proposed improvements are not designed
for the table used because the one in current use cannot be changed in terms of height or surface
area. Therefore, the proposal consists only of an ergonomic chair.
Seat length and width are determined based on hip width and popliteal length as in the
design of the previous chair. Meanwhile, the height of the chair is determined by reducing the
height of the bottom of the table with thick thighs based on anthropometric data. A footing is
made at the bottom of the seat so that workers can sit in an ergonomic position despite the fact
that the height of the chair designed is actually not ergonomic. The footing is made at a distance
of popliteal height from the surface of the chair itself. The width of the footing is determined
based on the length of the foot in anthropometric data. The size is chosen so that workers can
set their feet comfortably on the surface.
The next process that will be improved is the assembly process. The initial REBA image,
the ideal table and chair proposal, and the simulation for REBA calculations after using the
proposed improvements can be seen below.
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Application of the Reba Method to Osh Systems to Increase Work Productivity (A Case Study at
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Table 6. Evaluation and Improvement of Assembly Activities
A
B
C
D
Stickman
Illustration of
Activities
Proposed Tables
Proposed Dimensions of
Chairs
Illustration
Illustration
The assembly process will have the same calculation method as the installation process of
variations. The REBA score obtained on the proposed stitching activity performed while
standing amounts to 3. The proposed seat for this activity is also the same as the proposed seat
that has been designed for variation installation activities. Meanwhile, the proposed table is
also basically designed the same as the proposed table supplied for the installation of variations
and bartack activities. The element that distinguishes the proposed table for this activity is that
there is a protruding part on one side of the table that will face the operator. This protruding
part is made to accommodate a large sewing object.
At the table in current use, the stitching object is blocked by the table so the operator must
sit at a sufficient distance from the table. This indented section is made so that the stitching
object can enter the protruding part and the operator can sit closer to the table. The object sewn
in this process is generally a backpack. The backpack itself usually has a width that does not
exceed the width of the user's shoulder. Therefore, the shoulder width is chosen to determine
the diameter of the protruding part of the designed table.
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Table 7. Evaluation and Improvement of Bartack
A
Stickman
Illustration of
Activities
B
Proposed Tables
C
Proposed Dimensions of
Chairs
D
Illustration
Illustration
The next process that will be improved is the bartack process that can be seen above. The
assembly process will employ the same calculation method as the variation installation process.
The REBA score obtained from the proposed stitching activity carried out while standing
amounts to 3. The bartack activity is conducted by using a table size that is the same as the
table size for the stamp machine used in variation installation activities. Therefore, the
proposed table for this bartack activity has the exact same size as the proposed table size for
variation installation activities. The proposed table has a length, width and height of 960mm,
600mm and 600mm, with an additional stage as high as 56.5mm.
The proposed seat for bartack activities is the same as the proposed seat given for variation
installation activities. The same table height causes the proposed seat to be given. Thus, the
proposed chair designed for variation and bartack installation activities has a length of
361.1mm, width of 485.6mm, and height of 412.1mm.
After making a proposal, the REBA score for variation installation activities using
proposals that have been made will be recalculated. The REBA score calculation is made in
the same way as before. Overall, the risk for the nine activities decreased. The reduced risk of
existing activities is caused by the use of ergonomic tables and chairs by workers. This
ergonomic desk and chair causes the worker's posture to be ergonomic as well.The ergonomic
posture in question shows an upright neck and back position, with the upper arm parallel to the
torso and the forearm bent at a 90 degree angle, and the leg bent at a 90 degree angle as well.
This ergonomic posture can be seen in the table simulation image and the chair proposal made
for the calculation of the REBA score after using the proposed improvement. Thus, the risks
carried by workers when carrying out these activities is also bound to be reduced.
The proposed improvements made lowered the REBA score for the four activities.
Below follows the recapitulation table of the fourth REBA score process.
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Application of the Reba Method to Osh Systems to Increase Work Productivity (A Case Study at
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Table 8. REBA Score Recapitulation Proposed Improvement
No
1
2
3
4
Process
Installation of
Variations
Stitching in Standing
Position
Bag Assembly
Bartack
Initial Score
REBA
Risk
Propose Score
REBA
Risk
10
High Risk
3
Low Risk
9
High Risk
3
Low Risk
8
8
High Risk
High Risk
3
3
Low Risk
Low Risk
The results of repairs involving relevant parties led to the design of tables and chairs that
attained a safe Reba Score (as seen in Table 8). With the design concept, it will certainly
produce a work system that is in accordance with the anthropometry of the operators who carry
out their work [3,9,22,28]. Another benefit for companies is that employees feel at home
working, the absence rate of employees is lower, and the work atmosphere is improved to a
greater extent. [10,27,30].
4. CONCLUSION
The results of the evaluation of the work system on the production floor indicate an average
REBA value of 7.33, implying a high risk. Improvements that can be made include the design
of 3 types of tables, 2 types of ergonomic chairs and improvements made to the body posture.
Overall, several types of designs will produce 6 work systems. The results of the improvement
with the two methods make the work system better with an average REBA score of 2.88.
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