Improvement of the Water Purifier Assembly Process to Reduce Process Time and Ergonomic Risk

DOI: 10.14416/j.ind.tech.2024.04.010

Abstract

This research studies the assembly process of water purifiers for the R and U models, aiming to determine standard times, improve the assembly process, design the standard working process, and reduce ergonomic risks. Since the assembly of water purifiers uses employees mainly in production, it can lead to worker fatigue. The results from the work and time study, determining the standard times, and analyzing man-machine charts, revealed that the filter tube testing process consumed a significant amount of time, and workers had idle time and engaged in unnecessary movements. To address these issues, we utilized the 5W1H questioning technique to investigate the problem. Subsequently, we applied the principles of ECRS and ergonomics to improve the process. This involved simplifying work procedures, rearranging the work sequence, establishing new workstations, and designing equipment for leak testing and timing. From the results, the standard time of each process was determined. The improvements significantly reduced the time required for filter tube testing for both the R and U models, reducing it from 514.97 seconds to 351.23 seconds, equivalent to a 31.8 percent decrease. Additionally, the ergonomic risk assessment for working postures was reduced from a high-risk level to a medium-risk level. Both the RULA and REBA scores decreased from 7 points to 4 points and from 10 points to 7 points, respectively.