A TRIZ-Supported Concept and Protocol Development for Roof Tile Transportation and Inspection Systems

Abstract

Currently, the use of manual labour in the transportation and inspection systems of leading roof tile manufacturing companies in Indonesia is still prevalent. Manual labour is usually labour-intensive, has higher risks of musculoskeletal disorders, and produces frequent occurrences of errors and losses. Furthermore, the current studies of suitable concepts and test protocols for roof tile transportation at the manufacturing stage as well as their inspection systems are not practicable in Indonesia. There is also no study that has used the theory of inventive problem-solving (TRIZ) in the development of concepts and protocols for roof tile transportation and inspection systems. Using TRIZ as a supporting tool, this study investigated the development of a transportation system to be employed during the manufacturing of the roof tile and a test protocol for their usability in Indonesian companies to overcome this concern. The study included screening and scoring concepts and usability test protocols identified from the existing literature, with the support of TRIZ tools such as the engineering contradiction, contradiction matrix, and inventive principles. Thus, the finalised concept comprised a belt conveyor system (Inventive Principle 20: Continuity of Useful Action) with a flipping mechanism for transportation and a vision-based camera for inspection. Results of the study showed that the concept excelled in cost, durability, reliability, versatility, low risk to the product, efficiency, and safety. The t-test protocol (Inventive Principle 23: Feedback) was selected based on the results due to its versatility in testing efficiency, reliability, and productivity. It was concluded that this concept has the potential to alleviate roof tile workers of physical work and reduce the prevalence of musculoskeletal disorders.