OTOMOTİV SEKTÖRÜNDE FAALİYET GÖSTEREN BİR İŞLETMEDE REBA YÖNTEMİ İLE ÇALIŞMA KOŞULLARININ İYİLEŞTİRİLMESİ

Abstract

Bu çalışma, Kocaeli'deki bir otomotiv işletmesinin fırın hattında vardiya başına yaklaşık 1.600 kez tekrarlanan kauçuk-mandıren takma ve çıkartma işlemlerindeki ergonomik riskleri REBA yöntemiyle değerlendirmektedir. Manuel takma ve çıkartma işlemleri sırasıyla 10 (yüksek risk) ve 11 (çok yüksek risk) puan almıştır. Başlıca risk kaynakları gövde ve boyundaki aşırı bükülmeler, dengesiz bacak yüklenmesi ve manuel kuvvet uygulamasıdır. Kaynağında önleme yaklaşımıyla sürece mekanik bir pompa entegre edilerek fiziksel yük operatörden ekipmana aktarılmıştır. Müdahale sonrasında her iki işlem için REBA skoru 3'e (düşük risk) düşmüştür. Bulgular, yüksek tekrarlı endüstriyel görevlerde manuel iş yükünü mekanik sisteme aktaran mühendislik kontrollerinin ergonomik riski belirgin biçimde azaltabileceğini göstermektedir.

Keywords

• REBA
• ERGONOMİ
• DURUŞ ANALİZİ
• KAS-İSKELET SİSTEMİ
• İŞ SAĞLIĞI VE GÜVENLİĞİ
• OTOMOTİV ENDÜSTRİSİ

IMPROVING WORKING CONDITIONS IN AN AUTOMOTIVE INDUSTRY COMPANY USING THE REBA METHOD

Abstract

This study evaluates ergonomic risks in rubber-mandrel mounting and removal operations performed approximately 1,600 times per shift on an automotive furnace line using REBA. Manual mounting and removal scored 10 (High Risk) and 11 (Very High Risk), respectively. The main risks were excessive trunk and neck bending, unbalanced leg loading, and manual force application. Following the prevention-at-source principle, a mechanical pump transferred the physical load from the operator to the equipment. After intervention, both operations scored 3 (Low Risk). The findings indicate that engineering controls which transfer manual workload to a mechanical system can substantially reduce ergonomic risk in high-repetition industrial tasks.

Keywords

• REBA
• ERGONOMIC
• POSTURE ANALYSIS
• MUSCULOSKELETAL SYSTEM
• OCCUPATIONAL HEALTH AND SAFETY
• AUTOMOTIVE INDUSTRY

References

1. Kaynaklar (References)
2. Ağar, A., 2025. Comparison of REBA, RULA and OWAS Ergonomic Risk Assessment Methods: An Example of a Car Tire Business. Journal of Engineering Sciences and Design, 13(1), 250-262.
3. Ahmadi, O., Sheikh Damenab, P., Abbaspour, A., Rasoulzadeh, Y., 2020. Musculoskeletal Disorders Risk Assessment in Serviceman Workers of a Petrochemical Company. International Journal of Musculoskeletal Pain Prevention, 5(3), 360-366.
4. Akın, N.M., Aydın, F., Yıldız, B., Gündüz, T., Özalp, T., 2022. Tekrarlı Manuel İşlerde Fizyolojik Zorlanmaların Değerlendirilmesi ve Önlenmesi. Ergonomi, 5(1), 43-54.
5. Chiasson, M. E., Imbeau, D., Aubry, K., Delisle, A., 2012. Comparing the results of eight methods used to evaluate risk factors associated with musculoskeletal disorders. International Journal of Industrial Ergonomics, 42(5), 478-488.
6. Darçın, M., Alkan, M., 2025. Ergonomic Risk Assessment in Heavy Equipment Manufacturing: A REBA-Based Analysis in a Crane Production Facility. The Journal of Applied Engineering and Agriculture Sciences, 2(1), 33-43.
7. David, G., 2005. Ergonomic methods for assessing exposure to risk factors for work-related musculoskeletal disorders. Occupational Medicine, 55(3), 190-199.
8. Fan, C., Mei, Q., Yang, Q., Li, X., 2022. Computer-Vision Based Rapid Entire Body Analysis (REBA) Estimation. Modular and Offsite Construction Summit, Edmonton, Canada.

9. Fathurohman, M., Sukapto, P., Susanto, S., 2024. Application of The Rapid Entire Body Assessment (REBA) Method to Improve Work Safety in The Automotive Spare Parts Industry. Jurnal Improsci, 2(1), 1-17.
10. Ghasemi, F., & Mahdavi, N. (2020). A new scoring system for the Rapid Entire Body Assessment (REBA) based on fuzzy sets and Bayesian networks. International Journal of Industrial Ergonomics, 80, 103058
11. Gürsoy Özcan, A., 2022. Application of REBA and Karakuri Kaizen Techniques to Reduce Ergonomic Risk Levels in a Workplace. Journal of Engineering Sciences and Design, 10(4), 1430-1444.
12. Hignett, S., McAtamney, L., 2000. Rapid Entire Body Assessment (REBA). Applied Ergonomics, 31(2), 201-205.
13. Huang, K., Jia, G., Wang, Q., Cai, Y., Zhong, Z., & Jiao, Z. (2024). Spatial relationship-aware rapid entire body fuzzy assessment method for prevention of work-related musculoskeletal disorders. Applied Ergonomics, 115, 104176.
14. Kansu, S., Parlak, T., Güneri, A.F., 2021. Kaynak İşlemlerinde Çalışan Personel İçin REBA Metodu İle Ergonomik Risk Değerlendirmesi: Kriyojenik Tank İmalatı Sektöründe Bir Uygulama. Mühendislik Bilimleri ve Tasarım Dergisi, 9(3), 952-968.
15. Karsh, B. T., Moro, F. B., Smith, M. J., 2001. The efficacy of workplace ergonomic interventions to control musculoskeletal disorders. Ergonomics, 44(6), 589-613.
16. Karhu, O., Kansi, P., & Kuorinka, I. (1977). Correcting working postures in industry: A practical method for analysis. Applied Ergonomics, 8(4), 199-201.
17. Kee, D., 2022. Systematic Comparison of OWAS, RULA, and REBA Based on a Literature Review. International Journal of Environmental Research and Public Health, 19(1), 595.
18. Kshirsagar, V.P., Awari, G.K., Singh, M.P., 2024. Digital Human Modeling for Ergonomic Assessment of Seated CNC Operator. ShodhKosh: Journal of Visual and Performing Arts, 5(7), 977-989.
19. Lal, M., Singh, A., Ali, S. A., & Das, S. (2026). CBRRES: a computer-based REBA and RULA evaluation system for musculoskeletal disorder estimation. International Journal of Occupational Safety and Ergonomics, 1-12.
20. Li, L., Martin, T., & Xu, X. (2020). A novel vision-based real-time method for evaluating postural risk factors associated with musculoskeletal disorders. Applied Ergonomics, 87, 103138.
21. McAtamney, L., & Corlett, E. N. (1993). RULA: a survey method for the investigation of work-related upper limb disorders. Applied Ergonomics, 24(2), 91-99.
22. Rahman, M.I.A., Osman, S.A., Osman, S.A., 2026. Assessing Ergonomic Risks in Laser Cutting Sheet Metal Operations Using REBA Method: A Case Study. Journal of Advanced Research Design, 144(1), 1-9.
23. Sandeep, K.G., Jayan, T.J., Muthukumar, K., 2020. Ergonomic Assessment in Vehicle Assembly Line using REBA Tool. International Research Journal of Engineering and Technology (IRJET), 7(3).
24. Sirikasemsuk, K., Kittipanya-Ngam, P., Luanwiset, D., Leerojanaprapa, K., 2024. Work Posture Risk Comparison of RULA and REBA Based on Measures of Assessment-Score Variability: A Case Study of the Metal Coating Industry in Thailand. International Journal of Innovative Research and Scientific Studies, 7(3), 926-935.
25. Sunardi, S., Yuniar, Y., 2024. Ergonomic Risk Assessment in Heavy Equipment Manufacturing & Automotive Wheel Installation Case. International Journal of Applied Science and Engineering Review, 5(2), 45-56.
26. Takala, E. P., Pehkonen, I., Forsman, M., Hansson, G. Å., Mathiassen, S. E., Neumann, W. P., Sjøgaard, G., Veiersted, K. B., Westgaard, R. H., Winkel, J., 2010. Systematic evaluation of observational methods assessing biomechanical exposures at work. Applied Ergonomics, 41(4), 471-481.
27. Wang, S., Li, J., Yin, M., & Wu, Q. (2025). Accessibility evaluation of assembly operations in confined space based on digital human model. International Journal of Industrial Ergonomics, 107, 103719.