Malayan Colleges Laguna S.Y 2012-2013

Fastech Synergy Philippines Incorporated Ergonomic Case Study
In Partial Fulfilment of the Requirements for the Course Ergonomics (IE115)

Submitted by:

Buenflor, Mary Abigail L. Cacayan, Gellie L. Nagpala, Ivan Jesrael E. Pablo, Mark Joseph E. Ramos, Charisse Joyce N.

Submitted to:

Prof. Ezrha C. Godilano IE115 – B31

December 3, 2012

INTRODUCTION

Established in 1983, Fastech is one of the leading providers of assembly and test services to the semiconductor integrated device manufacturers (IDM) in USA, Europe, and Asia. This company was formerly known as Circuit Packaging, Inc. and changed its name to Fastech Synergy, Ltd. in 1989. This is a Filipino-owned company and managed by Mr. Saturnino G. Belen, Jr., the current Chairman and Chief Executive Officer of the group. In 1992, Fastech has established a manufacturing site located in Light Industry and Science Park I, Cabuyao, Laguna, Philippines. Fastech Synergy Ltd. offers a complete range of manufacturing capabilities including the full spectrum of RF and microwave testing and tuning. It is positioned to meet high demand for semiconductor and microwave manufacturing services for applications in the field of computers, telecommunications, consumer and automotive products. Fastech Synergy has currently 359 employees consisting of 125 males and 234 females. It operates in three shifts: Shift A (6am – 2pm), Shift B (2pm – 10pm) and Shift C (6am – 6pm). Office working hours are from 8am to 5pm. It is subdivided into two departments, mainly, the Semiconductor Assemblies Segment and the Modules Assemblies Segment. The Semiconductor provides a broad range of services on turnkey contract manufacturing for semiconductor components and integrated circuits that support Pin-Through Hole (PTH) and Surface-Mounted Technologies (SMT) and products which include power translators, voltage regulators. It specializes in the assembly and test of micro packages, power discrete, plastics and niche/custom packages. On the other hand, Modules offers a complete range of manufacturing capabilities including surface mount, mixed and hybrid assembly with a full spectrum of RF and microwave functional testing and tuning which includes printed circuits board assemblies, microwave modules, and radio frequency devices. In addition, it involves in the trading of electronic products; and engages in the design and fabrication of component parts and tooling. Fastech Synergy can work with a customer to customize various product requirements and has a strong product development and Engineering team that is focused on offering better solutions to customer needs. Ergonomic hazards are significant issues in Fastech Synergy Philippines Inc. Many of the tasks in the company are characterized by highly repetitive movement patterns, prolonged hours of exposure to noise, insufficient amount of light for critical inspections, forceful muscle exertions, and awkward and static postures. These jobs increase the risk of a worker to acquire work-related disorders and injuries. This case study covers only the areas of the Modules Department office and Radio Frequency Interface System (RFIS) production under the same department. The main objectives of the researcher in doing this case study are the following:    To increase the awareness and knowledge of health and safety issues in the company To prepare records that provides information about the identification, assessment, and control of ergonomic hazards in the Modules Department of Fastech Synergy Philippines Inc. To reduce the risk of developing work-related disorders and injuries to the workers

DISCUSSION AND ANALYSIS
MODULES DEPARTMENT OFFICE

The Modules Department office is consists of people who are responsible for the client contact and service, decision-making, scheduling and planning. The office makes use computers only. Based from observation, there is no sufficient line inside the office, especially those in the front row desks.

Fig. 1. Modules Department Office

RADIO FREQUENCY INTERFACE SYSTEM (RFIS) PRODUCTION

The RFIS of Modules Department in Fastech Synergy caters three products, namely, Transistor, Diode and Virtual Routing and Forwarding (VRF). These products are manufactured simultaneously in the assembly line upon order of the customers. These products are then assembled by the operators in batch for each station. The supervisor is in-charged in the overall production of the line. In the assembly line, most operations require manual labor, and some are automatic and semi-automatic. The line uses machines for die attach, wire bonding, sealing, marking, and Fig. 2. RFIS Production Line Assembly testing. It also uses microscopes for keen observations, and computers for recording and keeping data of the line. A certain degree of temperature is sustained inside the line, and adequate amount of light is given to secure that every units are in good condition.

PROCESS DIAGRAM OF RFIS PRODUCTION LINE ASSSEMBLY
START Die Prep Die Attach Wire Bond 3rd Opt

Testing

Marking

Oven

Sealing

QA Gate

Packaging

Storing

END

Fig. 3. Process flow of the RFIS Production Line Assembly

This diagram shows the process flow of the RFIS Line assembly. First step is to inspect the die; this process involves transferring good dies from the wafer package to the glass plate. Once finished, the batch goes to the die attach process wherein the dies are assembled manually. The assembled units are inspected before it undergoes the wire bonding process. The wires are properly bonded in the assembly with proper height and correct number of wires. Next, it goes through the 3rd Optical inspection. If the product fails to conform the proper wiring, it will remain for rework. If it conforms, the product will undergo sealing, and then processed in the oven and ready for marking. The last steps are testing to assess the conformity of the product. Finally, it is set for packaging and stored in the cabinet for shipping.

COGNITIVE PERFORMANCE OF THE USER

Attention There are five types of attention which is selective, focused, divided, sustained and lack. We identified the type of attention that is done by the operator in each station. For example, die prep, die attach and sealing is done with focused attention. It means when doing the task; the operator pays careful attention only to this process (e.g. refer to figure 4). For QA and 3rd Opt, we categorized it to sustained focus because the person watches for a particular interest, such as a defect. Wire bond on the other hand ha a selective attention type because, the operator does not only check the unit but also the monitor and the other control that she uses in the process.
Fig. 4. Machine for Die Attach

Creativity The creativity of the line is fairly ergonomic. The wire bonding station (refer to image on the left), was designed for comfort of the operator. First, the black padding near the mouse is used to support the wrist. The operator uses the mouse during the entire work-shift. The platform under the table is used to help elevate the legs to proper sitting posture.

Memory The operators of the RFIS assembly line are multitasking. When one operator is finished with a task, to avoid having idle, the operator will do a different task on the other station.

Perception Each station in the line has graphical or visual displays. An example is the wire bonding station. The wire bond has a graphical display to keep the operator in track of the number of wires to be bonded on the component. Another example is the QA station. The QA station, on the other hand, displays visual representation such has code number for each kind of reject parameter.

Fig. 5. Wire Bonding Machine

Problem Solving The operators of the line follow a rule when something goes wrong with the station. They immediately approach the supervisor for any concern. In the line, machines are only knowledge-based when it comes to problem solving.

F i g. 6. Manual Wire Bonding Machine

Language Verbal language is used inside the line.

Thinking The equipment used are not that advance therefore the operator must be trained and be able to familiarize the controls.

Fig. 7. Laser Ink Marking Machine

POTENTIAL AND OBSERVED ERGONOMIC HAZARDS
 Modules Department Office Hazard: Sitting without adequate foot support and poor leg posture are difficulties to the worker. Placing the feet on the foot of the chair may result in the foot being positioned behind the knee. This stretches the quadriceps (thigh) muscles and also changes the orientation of the pelvis and the lower back. These postures place the lower back in a biomechanical poor position and can result in low back fatigue and soreness. Solution: There should be adequate foot support when sitting for prolonged periods of time. Sitting posture should involve feet positioned in front of the knee and the knee should not be lower than the hip in terms of vertical height.

Hazard: The monitor height is too low. The screen is below the worker’s line of sight. The wrists are bent backwards. This increases the pressure in the wrist joint and is associated with hand injuries. The keyboard tray clips are raised, giving the keyboard an angle that promotes wrist bending in users. Solution: the monitor height should be near the line of sight of the worker when their head and neck are in a neutral position. The mouse hand should be at the same level as the keyboard and the wrists should be in a neutral or straight position when typing.

Hazard: Poor lighting. It appears that there are insufficient amount of light in the office. Solution: The lighting standards for office computer work are in the range of 300 lumens. Additional lighting system should be provided in the office.



RFIS Production Line Assembly

 Noise

Figure 8. Noise Levels

This table shows the measured noise levels in the different areas inside the production line. Based on the assessment, the RFIS line conforms to the OSHA Standards.  Lighting

Figure 9 Illumination Reading

Based on the assessment, the lighting on some areas inside the production line is not enough. Thus, improvement on the lighting system such as adding more lights, decreasing the distance of the source light to working surface area, should be made in order to reduce the eye-related disorders.

 CTD Risk Analysis

Figure 9 CTD Risk Analysis of Die Attach

Based on the assessment, the CTD Risk Index resulted to 0.5864 which can be considered as optimal since it is below 1. The operator therefore of die attach is not prone to develop CTD.

Figure 9 CTD Risk Analysis of Sealing

Based on the assessment, the CTD Risk Index resulted to 1.8379 which is not acceptable to be optimal since it is greater than 1. The operator therefore of sealing is prone to develop CTD due to repetitive hand motions of applying the epoxy manually.

Figure 10 CTD Risk Analysis of Sealing

Based on the assessment, the CTD Risk Index resulted to 1.0159 which is not acceptable to be optimal since it is greater than 1. The operator therefore of die prep is prone to develop CTD due to repetitive hand motions of transferring 100 dies per cycle from its package to the waffle pack.

Based on the Rapid Upper Limb Assessment (RULA), the Die Prep, Die Attach, Wire Bonding, 3rd Opt, QA Gate, Sealing and Marking processes should be further investigated and improved. The operators has been experiencing too much twisting and bending of their neck, twisting of wrists, and poor arm positions. To reduce health disorders, Fastech Synergy is advisable to make changes on its method of processing the units of product. Meanwhile, in the Modules Department Office, the results showed that the area should also be further investigated, and change may be needed especially on the movement of the neck and the wrist of the employers.

Recommendation To reduce the work-related disorders in the company, Fastech Synergy should increase the awareness of safety and health issues among its employees. This is to ensure that workers are in safe condition and efficient in their work. It is also recommended that operators of the machine should be given enough training and education. Regarding the office of the Modules department, sufficient light should be provided especially those in the last row. Another primary concern is the tables because they are too small. Their desks should be replace and re-layout because they seem too compressed, and cannot do their task comfortably in long working hours. Ergonomic chairs are also recommended to relax their posture and prevent back pain; also as seen in the picture on clean room, their chair must be replaced with back supports.