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Análise ergonómica da atividade de trabalho numa indústria de montagem de máquinas de café
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Uma linha de montagem (LM) de kits de embalamento de máquina de café foi alvo de análise e intervenção ergonómica. Os objetivos foram avaliar o nível do risco de Lesão Músculo-Esquelética Relacionada com o Trabalho (LMERT) e comparar dois tipos de Workflow: “Single-piece production” e One-piece flow; intervir no layout e na inovação do processo de montagem, visando reduzir a probabilidade de ocorrência de LMERT´s e melhoria das condições de trabalho.
A análise ergonómica, por observação direta e verbalizações, permitiu compreender e caracterizar a tarefa e atividade, as suas etapas, o layout, as relações entre chefias de linha e operadores, e identificar as necessidades e constrangimentos da situação de trabalho. Em seguida, analisou-se o nível do risco de LMERT, através dos métodos RULA e OCRA Check-list. Estudaram-se 3 linhas de montagem idênticas, para perceber se existem diferenças no seu layout ou desvios entre o trabalho prescrito e o trabalho real. Após compreender a natureza da atividade de trabalho, compararam-se os dois registos de Workflow e fizeram-se propostas de melhoria.
Os operadores das LM´s apresentam níveis elevados de risco de LMERT em algumas montagens manuais, tendo sido identificadas propostas de melhoria para as tarefas analisadas. Confirma-se a existência de desvios entre a tarefa prescrita e real e diferenças entre as linhas de montagem. O Workflow “Single-piece production” apresenta desvantagens no nível do risco obtido, devido aos valores constantes dos scores dos segmentos corporais; no trabalho de pé; na movimentação dos operadores entre os postos de trabalho; e dificulta a aplicação de planos de rotação adequados.
O posto de trabalho OP.KE1 apresentou nível do risco Elevado, nomeadamente no segmento punho. A principal causa dos desvios entre o trabalho prescrito e real, foi a não utilização dos moldes de montagem. Apesar da linha LM13 ser recente, observaram-se pontos críticos que não existem nas restantes linhas. Conclui-se que é preferível realizar One-piece flow, apesar de ser contrário ao estabelecido internamente.
An assembly line (AL) of coffee machine packaging kits was the subject of ergonomic analysis and intervention. The objectives were to assess the risk level of Work-Related Musculoskeletal Injury (WRMSI) and compare two types of Workflows: “Single-piece production” and “One-piece flow”; intervention in the layout and innovation of the assembly process, aiming to reduce the probability of occurrence of WRMSI's and improve working conditions. Ergonomic analysis, through direct observation and verbalizations, made it possible to understand and characterize the task and activity, its stages, layout, relationships between line managers and operators, and identify the needs and constraints of the work situation. Next, the WRMSI risk level was analysed using the RULA and OCRA Check-list methods. Three identical assembly lines were studied to understand whether there were any differences in their layout or deviations between the prescribed work and the actual work. After understanding the nature of the work activity, the two Workflow records were compared and improvement proposals were made. AL operators present high levels of WRMSI risk in some manual assemblies, and improvement proposals have been identified for the analysed tasks. The existence of deviations between the prescribed and actual task and differences between assembly lines are confirmed. The “Single-piece production” Workflow presents disadvantages in the level of risk obtained, due to the constant values of the scores of the body segments; in standing work; in the movement of operators between workstations; and makes it difficult to apply appropriate rotation plans. The OP.KE1 workstation presented a high-risk level, particularly in the wrist joint. The main cause of deviations between the prescribed and actual work was the non-use of assembly molds. Although the LM13 line is recent, critical points were observed that do not exist in the other lines. It is concluded that it is preferable to perform One-piece flow, despite it being contrary to what is internally established.
An assembly line (AL) of coffee machine packaging kits was the subject of ergonomic analysis and intervention. The objectives were to assess the risk level of Work-Related Musculoskeletal Injury (WRMSI) and compare two types of Workflows: “Single-piece production” and “One-piece flow”; intervention in the layout and innovation of the assembly process, aiming to reduce the probability of occurrence of WRMSI's and improve working conditions. Ergonomic analysis, through direct observation and verbalizations, made it possible to understand and characterize the task and activity, its stages, layout, relationships between line managers and operators, and identify the needs and constraints of the work situation. Next, the WRMSI risk level was analysed using the RULA and OCRA Check-list methods. Three identical assembly lines were studied to understand whether there were any differences in their layout or deviations between the prescribed work and the actual work. After understanding the nature of the work activity, the two Workflow records were compared and improvement proposals were made. AL operators present high levels of WRMSI risk in some manual assemblies, and improvement proposals have been identified for the analysed tasks. The existence of deviations between the prescribed and actual task and differences between assembly lines are confirmed. The “Single-piece production” Workflow presents disadvantages in the level of risk obtained, due to the constant values of the scores of the body segments; in standing work; in the movement of operators between workstations; and makes it difficult to apply appropriate rotation plans. The OP.KE1 workstation presented a high-risk level, particularly in the wrist joint. The main cause of deviations between the prescribed and actual work was the non-use of assembly molds. Although the LM13 line is recent, critical points were observed that do not exist in the other lines. It is concluded that it is preferable to perform One-piece flow, despite it being contrary to what is internally established.
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Palavras-chave
Análise da Atividade de Trabalho Ergonomia Lean Production Lesões Músculo-Esqueléticas Relacionadas com o Trabalho OCRA One-piece Flow Produção de máquinas de café RULA Ergonomics Production of coffee machines Work Activity Analysis Work-Related Musculoskeletal Injuries