Ergonomic Improvements of Workstations for Visual Inspection and Electrical Tests in a Multimedia Product Factory

Abstract

Workstations for Visual Inspections (WVIs) and also for Electrical Tests (WETs) of a multimedia product factory were studied from Ergonomic viewpoints. The problems, identified by subjective assessments and direct observations, were related to poor designs of workstations, work processes and improper tools, causing high (12.2 ± 4.1 %) product returns. In some WVIs, operators were having visual fatigue due to excessive magnifying glass usage, glare from inspection templates and too many components to check within a very short period. Some WETs were not organised to reduce hands and body motions, and to eliminate confusing criteria for passing or failing of the tests. They also had poor visual projection tests due to too bright ambient illumination on the screen. The Ergonomic improvements were: the reduced usage of magnifying glass, the use of no-glare templates, visual inspection of only the electrically non-tested components, the re-design of WETs for economy of motion, the improvement on pass or fail criteria, dark space for effective visual projection tests, etc. These ergonomic interventions improved the company's productivity and operators' health, reduced the product returns and saved USD 70,900 per month.