Jurnal Sistem dan Manajemen Industri Vol 4 No 1 July 2020, 30-40 30 http://dx.doi.org/10.30656/jsmi.v4i1.1997 Design of tools to reduce the risk level of work postures at warping station Indira Kusuma Wardani*, Irwan Iftadi, Rahmaniyah Dwi Astuti Department of Industrial Engineering, Universitas Sebelas Maret, Jalan Ir.Sutami No. 36A, Surakarta, Jawa Tengah 57126, Indonesia ARTICLE INFORMATION ABSTRACT Article history: Received: January 16, 2020 Revised: June 19, 2020 Accepted: June 24, 2020 Based on the REBA analysis, there is a risky operator work postures in the warping work station at PT. Iskandar Indah Printing Textile because they do not use work tools. The assessment of the level of work posture risk by the REBA method gets the result that the highest work element with a final score of 10 is obtained by taking warp yarn at the warping station. This study aims to produce a design tool to reduce the level of work posture risk in warping work station operators. Then the design of tools was carried out by the Pahl and Beitz method to produce three alternative product design concepts. Based on the three ideas, the best plan is chosen by using an Engineering Design Selection, and the result is the second design concept. The selected design is an adjustable trolley with a vertical screw drive system that is comfortable to use and does not cause a bending position on the operator because it has a trolley plate that can be adjusted in height as needed. The use of the trolley causes a decrease in the level of work posture risk from a high-risk level to a small risk level with a final score of 10 to 3. Keywords: Product design REBA Pahl and beitz method Trolley *Corresponding Author Indira Kusuma Wardani E-mail: indiraksma@gmail.com This is an open-access article under the CC–BY-NC-SA license. © 2020 Some rights reserved 1. INTRODUCTION In the industrial world, material handling work is still done manually until now. The work is known as Manual Material Handling (MMH). MMH, which consists of pushing, lifting, lowering, carrying, and pulling, is the primary source of employee complaints in the industry [1]. The selection of humans as workers in handling material has an advantage that is being able to adjust movement to facilitate the transfer of loads in tight spaces and irregular work. However, MMH activities have some risks when applied to the wrong working attitude, working aids, and inadequate working environment conditions [2]. MMH activity, which results in bending and turning positions, should be reduced or, if possible, corrected because this attitude is prone to disorders of the musculoskeletal system [3]. Work posture is the link between the dimensions of the worker's body with the aspects of the tool at his workplace [4]. Strange work postures, lifting movements, forceful movements, and high-speed manual work contribute to musculoskeletal disorders [5]. Musculoskeletal complaints are complaints on the part of the skeletal muscle that is felt by someone ranging from mild to severe complaints [6]. One study of Available online at: http://e-jurnal.lppmunsera.org/index.php/JSMI Jurnal Sistem dan Manajemen Industri ISSN (Print) 2580-2887 ISSN (Online) 2580-2895