Ergonomic design for musculoskeletal disorder prevention in the chemical processing industry: Case study on weighing stations and transfer of liquid catalysts

Manual material handling at storage transfer stations and weighing liquid catalyst raw materials in the chemical process industry leaded to a high risk of musculoskeletal disorders among workers. These work activities often involved awkward postures, twisting, bending and limited physical space. Work conditions were often cold and slippery, but there is limited equipment for transferring and weighing liquid catalyst raw materials into containers. Study objective to develop an ergonomic work system design for the process of transferring and weighing liquid catalyst raw materials (Perbuthyl ND-75, Perhexyl PV-75 and Percmyl ND-75). Design manual material handling tools using People Object Environtment Message & media Service (POEMS) framework and Social, Physical, Identity, Communication and Emotional (SPICE) development. The more optimal work posture design was simulated by using CATIA software with the aim to reduce the RULA score. The result of the study was to design manual material handling tools on the storage transfer stations and weighing liquid chemical raw materials, such as adjustable conveyors, trolleys and semi-mechanic weighted tools. While the result of the work posture measurement using RULA method obtained score reduction by three levels. This study concluded that simulation work activity by CATIA software with additional manual material handling tools, such as adjustable conveyors and trolleys, as well as the modification of semi-mechanical weighing devices, could reduce potential work-related musculoskeletal disorders (WMSDs) and chemical liquid spill hazards.