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Volume 5 , Number 1, February.2011
ISSN 1995-6665
Pages 9 - 16

Jordan Journal of Mechanical and Industrial Engineering

Jig Design, Assembly Line Design and Work Station Design and their Effect to Productivity
Adi Saptari, Wong Soon Lai, Mohd. Rizal Salleh
Faculty of Manufacturing Engineering
Universiti Teknikal Malaysia Melaka, Hang Tuah Jaya, Ayer Keroh, 76100 Melaka, Malaysia

___________________________________________________________________________
Abstract
This report discussed the effect of workstation design, assembly design, jig design and working posture on the assembly of plugs. Two different designs of jig (vertical and rectangular) and two sets of assembly line design (one and two operators) and two set of workstations design (sitting and standing) were studied to observe their effects to productivity. Design of
Experiments 23 with two levels of each factor is used to conduct an experiment for obtaining the most productive jig and assembly line design. Two groups of workers were employed to assemble the plug in 8 different ways. Number of replication is 32 for each setting and total of electric plugs produced by each group is 256 units. The results shows that jig design have the most significant effect to the assembly time. Furthermore, the other factors: assembly design and workstation design are also show significant factors to assembly time. However, interaction combinations of two or three factors were not significant to assembly time. The most productive assembly line design which achieved the lowest assembly time is the combination of one operator, with rectangular jig and work station design sitting. Meanwhile the working posture of workstation design that provides the lowest RULA score was sitting position, it provided score 2 which is safe.
© 2011 Jordan Journal of Mechanical and Industrial Engineering. All rights reserved

Keywords: Jig design, design of assembly, workstation design, productivity, working posture.

___________________________________________________________________________
1. Introduction
An assembly line is designed by determining the sequences of operations to manufacture of components as well as the final product. Each movement of material is made as simple and short as possible, with no cross flow or backtracking. All operations performed along the line are balanced. Design of assembly line plays the important role in manufacturing which will directly influence its productivity.
Previous researchers [13], [19-20] explained assembly line is a widely used in production systems. The main objective of assembly lines designers is to increase the efficiency of the line by maximizing the ratio between throughput and costs. Chow [5] stated that “A simple process design criterion is to balance the assembly line so that each operation takes approximately the same amount of time. A balanced line often means better resource utilization and consequently lower production cost.” Jig is a special tool used for locating and firmly holding work piece in the proper position during the manufacturing or assembly operation. It also guides the tool or work piece during the operation. Jig is designed to increase the productivity of operation assisting worker to do job easier, faster and more comfortable.
Meanwhile, applying principles of ergonomics in the job environments such as improving working posture and workstation design as part of ergonomics efforts on enhance productivity and safe working condition have been extensively discussed by many authors [7] [8] [2]

[22]. The studies discussed ergonomics intervention may improve productivity, quality, operators’ working condition, occupational health and safety (OHS), and even cost effectiveness. The areas of working environment studied include workplace layouts, working tables and chairs of appropriate height, fixing hand-tools, better lighting and job rotation and also working postures.
This research studied several parameters afore mentioned:
i.e. design of workstation, design of assembly process, design of jig, their effects to productivity in the assembly line of plugs. Other variables such as equipment and skill of worker which may contribute to productivity are assumed kept constant. The hypothesis to be tested that either one or more of the parameters or combinations of parameters contribute to better production performance in this case assembly time or cycle time.
Two designs of jig were introduced, one has rectangular shape and the other has line or vertical shape or vertical orientation. Two design of assembly were tested one with single operator and the other with two operators.
Design of workstation was created by applying common industrial practices in assembly line i.e. standing or sitting position. For working poster assessment, RULA
(Rapid Upper Limb Assessment) analysis was conducted to examine different workstation designs effect to safe working postures.
2. Methods
2.1 Product Design
For the purpose of this experiment an electric product was chosen as a case. This product was selected since it

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© 2011 Jordan Journal of Mechanical and Industrial Engineering. All rights reserved - Volume 5, Number 1 (ISSN 1995-6665)

widely used in the household, it was not a complex in design and components. The design of product is shown in Figure 1. This electric product is a plug product number BS 1363, it has 8 components. These are: base cover, neutral pin, earth pin, live pin, fuse holder, fuse, top cover and one screw. The dimension of the product is shown as Figure 1. Plug can assume as rectangular block
(dimension 51mm X 49 mm X 21 mm) with 3 pin (earth, neutral and live terminal pin). The central point of live and neutral pin is located 22 mm below the central point of earth pin. The distance between central point of live and neutral pin is also 22 mm. Accuracy of position and dimension of the plug’s pin are important when design the jig, this is to let plug able to locate and secure through the jig.

Figure 2 Two jig designs, a vertical shape and a rectangular shape
2.3 Design of Assembly line

Figure 1 Plug design and dimensions
2.2 Design of Jig
The purpose of jig on this research is holding the plug’s earth pin with cover in the proper position, other components locate and secure into the jig when the assembly process.
Two jigs were designed and produced by researchers, these designs were based on industry practice. The two were differentiated based on its orientation. The first one has orientation vertical shape in one line; the other has rectangular shape (see Figure 2). The size of the jig, the vertical one has 275 mm x 80 mm; the rectangular one has 136 mm x 145 mm. Both Jigs can accommodate 4 plugs at one time.

Two designs of assembly line were created these were based on manufacturing practices one with single operator and the other with two operators. The process of designing assembly as follow: at the first stage was to recognize components and the second stage was to comprehend assembly processes of product which is
BS1363. Once it has done, the assembly processes sequence were determined. These sequences as follow: put plug’s base cover on the jig, insert the child components (neutral pin, earth pin, live pin, fuse holder and fuse) into the base cover. Then, assembly the top and base cover together by screw. For screwing process, the jig is flipped and tightens with the screw driver powered by air pressure. The sequence planning for the assembly process of electric plug is presented in the precedence graph below:

1 – Place base cover on jig
2 – Insert earth pin
3 – Insert neutral pin
4 – Insert live pin

5 – Insert fuse holder
6 – Insert fuse
7 – Put top cover
8 – Screwing process

Figure 3: Precedence graph of plug assembly
Table 1is shown the result of each assembly task based on the precedence graph constructed in Figure 3. To obtain the balance of time for two operators, the assembly tasks assigned for each operator should be equal for eliminating the waiting time of another operator.

© 2011 Jordan Journal of Mechanical and Industrial Engineering. All rights reserved - Volume 5, Number 1 (ISSN 1995-6665)

11

Table 1: Average time of each plug assembly task for line balancing
Cumulativ
Average
Task
Assembly e time per
No.
Task
Assembly
plug (sec)
Time
Place base 0.83
0.83
1 cover on jig
Insert
earth
2.52
3.35
2
pin
Insert neutral
1.94
5.29
3
pin
Insert live pin
2.46
7.75
4
Insert fuse 1.91
9.66
5 holder Insert fuse
2.30
11.96
6
Put top cover
2.02
13.98
7
Screwing
5.02
19.00
8
process
According to the table above, the total time for assemble one electrical plug is 19.00s. The single operator did all the tasks from the beginning to the end of assembly processes. For design of two operators, in order to obtain a good line balancing for 2 operators, the total assembly time must divide equally into two, which is 9.5 sec.
Hence, the most nearly cumulative assembly on Table 1 is on task 5 which is 9.66 sec. This means that the first operator will stop at the end of task 5 which is insert fuse holder. The second operator will start from task 6, insert fuse to final assembly. Assuming that there were work in process, therefore, the second operator did not required waiting for the first operator and could start the experiment at the same time.
2.4 Design of Workstation
Workstation design of an assembly line may contribute to performance of workers when he or she performed his/her job on position either standing or sitting. Grandjean [11] has made exploration on work surface height for different kinds of jobs. He proposed precision work for men should be set at 100-110 cm, light work around 90-95 cm and heavier work around 7590 cm. Since the assembly of plugs is considered as a light work, the workstation design for assembly was set at the height 91 cm for either standing or sitting position.
2.4.1 Standing Position
Figure 4 shows isometric, and front side views, while performing the task with an operator and in standing position. The table height is fixed to 91 cm.

Figure 4: Standing position, isometric view and front view 2.4.2 Sitting Position
Figure 5 illustrates isometric and front side views of a subject performing the task with an operator in sitting position. The table height is fixed to 91 cm.

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© 2011 Jordan Journal of Mechanical and Industrial Engineering. All rights reserved - Volume 5, Number 1 (ISSN 1995-6665)

given prior to the experiment. This was necessary to ensure that learning time has reached. Their time was recorded to ensure the consistent performance of their jobs. 3. RESULT & DISCUSSION
3.1 Group’s Performance

Figure 5: Sitting position, isometric view and side view
2.5 Design of Experiment
The design of experiment took three factors and two levels (23), the factors were jig design, assembly design and workstation design. The first factor, jig design, it has two different designs. The second factor, assembly design, it has two levels, one single operator and two operators. The third factor, workstation design, with two levels the first setting was sitting the second setting standing. Based on this design eight (8) different ways of assembling line were formed. Table 2 shows the design of experiment for assembly line.
Table 2: Summary of Design experiment
One Operator
Two Operators
Position
Vertical
RectanVertical
Rectan jig gular jig jig gular jig
Standing
X1
X2
X5
X7
Sitting
X3
X4
X6
X8
2.6 Experimental Procedure
Two groups of worker participate in this experiment.
Each group has two subgroups, one with single operator and the other with two operators. These two groups will be compared and test whether their performance were the same, and whether the results of experiment were consistent. Each group performed 8 different sets of assembly process according to the full factorial design. Thirty two repetitions for each different set of assembly were done.
Each set was selected randomly, once it was selected, 32 plugs were produced. Hence, total of electric plug required to assemble for each group are 256 electric plugs. Measurement of performance for this experiment was the assembly time required to finish one product. Before recording the assembly time, the performance of each group was tested to ensure their work has reached a consistent performance. The assembly time or cycle time was recorded by using stop watch. This assembly time became the dependent variable, while different factors were set as independent variables.
2.7 Subjects
The subjects participated in this experiment were young workers age in average 24 years old, all were male subjects. Their height is on range of 170 – 180 cm. They have experiences and involved in industrial works for less than a year. Training to assembly this product was

The First test is to verify whether two groups of workers have different quality of work or performance.
This is necessary to make sure the inferences made from the results may work for both groups. Hence, the F test and t-test were used to examine whether two groups showed different performance. The F test were used to verify whether the group has significant different in variance. Based on the F test result, these two groups then were tested for t-test: paired two samples for means.
Table 3: t-test: paired two sample means between two groups Group 1 Group 2
Mean
19.564
19.739
Variance
1.397
1.027
Observations
256
256
Pearson Correlation
0.255
Hypothesized
0.000
Mean Difference
Df
255 t Stat
-2.080
P(T

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