İŞ YERİNDE ERGONOMİK RİSK DÜZEYLERİNİ AZALTMAK İÇİN REBA VE KARAKURİ KAİZEN TEKNİKLERİNİN UYGULANMASI

Öz

Tekrarlayan işler ve uygun olmayan vücut duruşları ile yapılan işler kas-iskelet sistemi rahatsızlıklarına ve iş gücü kayıplarına neden olmaktadır. Tasarım, teknoloji ve insan ergonomik koşullarda bir araya gelmelidir. Bu çalışmada, hızlı tüm vücut değerlendirme yöntemi ile otomotiv üretim hatlarında çalışanların maruz kaldıkları ergonomik risk seviyeleri belirlenmiş ve risk seviyesi yüksek olan bir hatta antropometrik ölçümler ve ergonomik vücut duruşları dikkate alınarak Karakuri çalışma prensibine göre raf sistemi tasarlanmıştır. Bilgisayar destekli tasarım sayesinde üretim öncesi sistemin çalışması simüle edilmiş ve ergonomik risklere yönelik çözümler sunulabilmiştir. Mevcut durumda “yüksek” olan ergonomik risk seviyesi, yeni tasarlanan mekanizma ile azaltılabilmiş ve çalışanlar için ergonomik bir çalışma alanı sağlanabilmiştir. Yeni durumda ergonomik risk seviyesi “düşük”tür. Ergonomik iyileştirmelere ek olarak, çalışanın manuel taşıma işleri ortadan kaldırıldığından, ilk durumda 120 saniye olan hattın çevrim süresi, Karakuri mekanizmasının kullanımından sonra 100 saniyeye düşürülmüş ve hattın verimliliği %17 artmıştır.

Anahtar Kelimeler

• Ergonomi
• Ergonomik tasarım
• Kaizen
• Karakuri
• Hızlı tüm vücut değerlendirmesi

APPLICATION OF REBA AND KARAKURI KAIZEN TECHNIQUES TO REDUCE ERGONOMIC RISK LEVELS IN A WORKPLACE

Öz

Repetitive works and the works done with inappropriate body postures cause musculoskeletal disorders and workforce losses. Design, technology, and humans must come together in ergonomic conditions. In this study, the ergonomic risk levels that employees in automotive production lines being exposed to were determined by the rapid entire body assessment (REBA) method and by considering anthropometric measurements and ergonomic body postures at a line with high risk level, and a shelf system was designed in accordance with the Karakuri working principle. Through the computer-aided design, the system operation was simulated and solutions for ergonomic risks could be provided before the production. The ergonomic risk level, which was “high” in the current situation, could be reduced with the newly designed mechanism, and an ergonomic workspace could be provided for employees. In the new situation, the ergonomic risk level is “low.” In addition to ergonomic improvements, as the manual transportation works of the employee were eliminated, the cycle time of the line, which was 120 s in the first state, was reduced to 100 s after the use of the Karakuri mechanism and the efficiency of the line increases by 17%.

Anahtar Kelimeler

• Ergonomics
• Ergonomic design
• Kaizen
• Karakuri
• Rapid entire body assessment

Kaynakça

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