EVALUASI DAN USULAN PERBAIKAN POTENSI BAHAYA ERGONOMI PADA GUDANG SERVICE PART LOGISTIC DIVISION PT. TOYOTA ASTRA MOTOR

• Main Author: Firdaresa, Laviola
• Format: Final Project
• Language: Indonesia
• Online Access: https://digilib.itb.ac.id/gdl/view/74342
• Institution: Institut Teknologi Bandung

This study evaluated ergonomic hazard at PT Toyota Astra Motor (PT TAM). PT. TAM is the official distributor of Toyota and Lexus cars in Indonesia. Not only car units, PT.TAM also manages the distribution of spare parts handled by the service part logistic division (SPLD). SPLD business flow process started from material order until material shipping . The main activity of SPLD is warehousing which consists of material handling and involves physical activity and manual handling. Based on the results of the SPLD clinic medical history, it was found that 17% of cases were work-related musculoskeletal disorders (WMSDs). The further investigated evaluation of WMSDs was using the Cornell Musculoskeletal Discomfort Questionnaire (CMDQ) and the result showed that 91% of SPLD warehouse employees had WMSDs symptoms with the worst part was in the waist (27.33%), neck (10.31%), and right shoulder (7.33%). The evaluation continued to the workstation evaluation stage at three selected workstations, which were glass packaging, Toyota Motor Oli (TMO) collection, and clutch cover packaging. The evaluation was conducted using three assessment methods, rapid whole body assessment (REBA), ergonomic risk factor checklist (ERFC), and recommended weight lifting-lifting index (RWL-LI). The results showed that the glass packaging workstation has a high ergonomic risk (REBA: 14; ERFC: 11; RWL-LI: 1.05). The TMO picking workstation also has a high ergonomic hazard risk (REBA: 13; ERFC: 14; RWL-LI: 6.57). While the cover clutch packaging workstation has a medium risk level (REBA: 7; ERFC: 5; RWL- LI: 0.18). The evaluation continued with the identification of root causes that support the occurrence of potential ergonomic hazards. The root cause of the problem was found to be the suboptimal actual evaluation method, no clear role of jobdesk in an improvement project, and lack of skills related to ergonomic design. In conclusion, SPLD had a high prevalence of discomfort rate and high risk ergonomic workplaces. The improvement design was needed to carried out to reduce potential ergonomic hazards. The solution design for the glass packaging workstation were changes in cardboard design, changes in layout, and the use of tools for styrofoam installation. The improvements for the TMO picking workstation was the use of lifting tools, portable vacuum hoist lifting. And for the proposed improvement of the cover clutch packaging workstation was the addition of an extended flexible arm to the vacuum hoist that has been installed. The proposed improvements to answer the root cause problem were the creation of an ergonomics design job desc matrix, the design of integrated ergonomics training, and the creation of a semi-automatic ergonomics evaluation method.