International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 02 Issue: 05 | Aug-2015 www.irjet.net p-ISSN: 2395-0072 © 2015, IRJET ISO 9001:2008 Certified Journal Page 1373 RULA Analysis of Work-Related Disorders Of Foundry Industry Worker Using Digital Human Modeling (DHM) S. C. Mali 1 and R. T. Vyavahare 2 1 Department of Mechanical Engineering, SVERI’s College of Engineering (Polytechnic), Gopalpur, Pandharpur, Taluka-Pandharpur, District-Solapur, Pin-413304, Maharastra, India. 2 Department of Mechanical Engineering, SKN Sinhgad College of Engineering, Korti, Pandharpur, Taluka-Pandharpur, District-Solapur, Pin-413304, Maharastra, India. Abstract: Ergonomic troubles are major issues faced by the metalwork manufacture. The ergonomics principles play very life-sustaining role in operators’ productivity. The two factors such as workstation layout and work design are important for operators’ or workers’ efficiency. Work-Related Musculoskeletal disorder (WMSD) is the common health problems of the industrial workers. This health problem can lead to long term effect on the output performance. The objective of this work is to study the postures of industrial worker in foundry industry using the RULA assessment using CATIA V5R19 software. The working postures were modelled in the CATIA V5 R19 software and then RULA assessment was conducted. From the RULA analysis, several awkward postures were detected with high in risk ingredients. This paper presents an ergonomic evaluation of workstation in a one foundry industry at sangali in Maharashtra state. The Various key postures of the workers were evaluated . Also study includes suggestions for the improvement. Tools like Rapid Upper Limb Assessment (RULA) and digital human manikin (DHM) were used in this study. Keywords: Ergonomics, RULA Analysis, WMSD, Posture, CATIA, DHM. 1. Introduction Industrial workers are easier to be exposed to discomfort and pain at work. The occupational risk factors are the biggest factors to these health problems and it can be found in any industries (Halim, et al. 2005). MSDs are able to degrade the health of the workers thus reduces the workers' performance in completing their tasks. Several literatures had suggested that the effect of low performance by the workers can have significant economic and social consequences [4, 5, 6, 7]. This can be seen by the compensation claims for the employers that are increasing which may overburden the health system [8, 9]. One of the major reasons for sick leave and work injuries in the industry is due to the inefficient of production ergonomics. Moreover, manufacturing companies had lost a huge amount of money in their resource budget to support the staff replacement and rehabilitation. Reports from many researchers had stated that production interruption and companies’ inefficiency may be caused by the high staff turnover and sick leave [11, 12, 13]. Because of this downside, it is important to ensure the health of the workers and their postures is one of the factors that need to be considered closely in running certain work task. A basic analysis of a work task can depend on questionnaires, interviews and video analysis. In addition, numerous measurements commonly known as assessment method can be used for physical risk assessment of job activities, usually specific to a body part or a type of activity. There are various ergonomic assessment method of manual tasks exist in the market. For example, are the RULA, REBA, OWAS, LUBA, QEC, PATH and PEO method [14, 15, 3]. Rapid Upper Limb Assessment (RULA) index is one of the most cited and commonly used tools for evaluating ergonomic risk of work-related MSDs [15, 16]. RULA is a subjective observation method for posture analysis that focuses on the upper part of the body with the particular attention to the neck, trunk and upper limbs [17, 18, 15]. Observational methods based on videotaped work task sequences to analyze various kinds of manual tasks with certain software are widely used nowadays because of its practicality and affordability [19, 15]. When designing a new task, another option is to use digital human models.