Redesign of Work Chairs and Tables to Reduce Musculoskeletal Disorders and Motion Waste at CV Barokah Gemilang Sejahtera
Keywords:
Anthropometry, Ergonomics, Motion Waste, Musculoskeletal Disorders (MSDs), Rapid Upper Limb Assessment (RULA).Abstract
CV Barokah Gemilang Sejahtera (BGS) is a garment industry producing ready-to-wear clothing. Observations and Nordic Body Map (NBM) questionnaires involving 14 sewing operators identified musculoskeletal complaints in the upper neck (82%), lower neck (84%), and back (91%). Operators also experienced motion waste caused by searching for sewing tools that were not systematically organized. This study aimed to redesign ergonomic work facilities to reduce Musculoskeletal Disorders (MSDs) risk and motion waste. The research employed NBM to identify MSD complaints, Rapid Upper Limb Assessment (RULA) to evaluate working posture, anthropometry to determine workstation dimensions, and the Right-Hand–Left-Hand Process Chart (PTKTK) to analyze inefficient movements. Data were collected through observations, interviews, anthropometric measurements, questionnaires, and work-activity documentation. RULA assessment produced a final score of 7, indicating a very high postural risk requiring immediate improvement. PTKTK analysis showed motion waste associated with sewing-tool searching, with work efficiency of 70.21% before improvement. The proposed redesign consisted of an adjustable chair with a height range of 68.9–80.3 cm and an adjustable table with a height range of 72.6–90.2 cm, complemented by a partitioned drawer. The proposed design projected a cycle-time reduction from 47 to 29 seconds and efficiency improvement to 82.75%, supporting improved posture, reduced MSD risk, and minimized motion waste.
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