National Symposium on Advancements in Ergonomics and Safety (ERGOSYM2009), 1-2 December 2009, Perlis, Malaysia 87 Ergonomic Design of Material Handling Tasks with Buffer Stock in Production System for Effective Operations DR.Bhuvenesh Rajamony School of Manufacturing Engineering University Malaysia Perlis UniMAP, 02000 KualaPerlis, Malaysia Tel: 604-9772615 ® 604-9798164(O) Fax: 04-9798160 Email: bhuvenesh@unimap.edu.my Abstract- The use of ergonomics study is to improve the workers safety and health, increase job satisfaction and enhances performance. Lack of ergonomics criteria in workspace and workstation design can cause physical and biological hazards to the workers. Ergonomics evaluations in industrial setting have recently received increased attention due to the cost incurred as a result of repetitive motion injuries. In Flexible Manufacturing System, the human capabilities and limitations must be respected to ensure safe effective operations. The material handling tasks, workplace and the equipment must be designed so they are easy to operate which eliminates strenuous labor. Supplies of unfinished workpieces called buffer stock put in front and behind each workstation eliminate time pressure for the worker. This arrangement gives much flexibility and better organized at work. This can lead to improved productivity in the Flexible Manufacturing System. The ergonomic design and equipment selection with buffer stock must be safe for the human operators and Flexible Manufacturing System. Keywords- Ergonomics, manufacturing, safety, industry, workplace I. INTRODUCTION A production system which includes Flexible Manufacturing System (FMS) typically possesses multiple automated stations and is capable of variable routings among stations. Its flexibility allows it to operate as a mixed model system. The FMS integrates into one highly automated manufacturing system many of the concepts and technologies, including: flexible automation, CNC machines, distributed computer control, robotics, automated material handling and storage. A flexible manufacturing system (FMS) is an arrangement of machines.... interconnected by a transport system. The transporter carries work to the machines on pallets or other interface units so that work-machine registration is accurate, rapid and automatic. A central computer controls both machines and transport system... [1] II. MANPOWER REQUIREMENTS Human resource development, equipment operator skills, manufacture of processing tools, products, processes & machinery, research and development are some of the issues resulting from higher level of technology implementation. In this situation, a contingency strategy for training engineers and other specialists with FMS should be considered in university learning with engineering education. These evolving trends in industry must be applied back into the engineering curriculum. Industry needs universities to respond with increase emphasis on design and manufacturing skills. III. TRAINING COMPETENT ENGINEERS Production system training in the university laboratories, increases the capability of engineers provides a distinct advantage for manufacturing industries. The proposed approach should be developed and implemented economically with the desired experience exists inside the university and the experience level of the teaching staff with the technological approach is high, its use should be considered, Fig.1. Fig. 1 Training manufacturing engineering students with material handling tasks in the laboratory. A. Reasons why storage buffers are used on automated production lines There are a number of reasons why storage buffers are used on automated production lines. Fig.2. The reasons include: • To reduce the effect of station breakdowns. Storage buffers between stages on a production line permit one stage to continue operation while the other stage is down for repairs. • To provide a bank of parts to supply the line. Parts can be collected into a storage unit and automatically fed to a downstream manufacturing system.