Beruflich Dokumente
Kultur Dokumente
PROCESS
Poppy Nandasari
Bambang Suhardi
Susy Susmartini
Department of Industrial
Department of Industrial
Department of Industrial
Engineering
Engineering
Engineering
Faculty of Engineering
Faculty of Engineering
Faculty of Engineering
Surakarta, Indonesia
Surakarta, Indonesia
Surakarta, Indonesia
nandapoppy@gmail.com
bambangsuhardi_ugm@yahoo.co.id susysus2011@gmail.com
anthropometry, with the risk level has decreased from the previous one. So the result
of this design deserves to be continued
Keywords batik, RULA, NBM, product design, gawangan, chair, value engineering
I. INTRODUCTION
One of the Indonesian cultural properties is batik. According to manufacturing
technique, the batik can be divided into three kinds of written, stamp and printing
batik. Written batik is a batik fabric in its manufacturing formed a motif or style of
batik used hand and canting (spouted tools) [7]. Each sheet of batik fabrics made with
this technique with painstaking that takes a long time to complete. Batik fabric has a
characteristic that does not exactly match the shape of each fabric so as to make batik
fabric the price is very expensive.
In producing batik needed various equipment operated manually. Tools used
including of frying pan, brazier or stove, canting, gawangan, pendulum, fabric,
wax/malam, pattern, table, dye vessel, wax solvent vessel, scrape tools, washbasin,
clothesline, and dyes [7]. The production process of a piece of batik is through the
process of examination materials, soaking, batik pattern making, pencantingan,
pelorotan (fabric is put in a hot tub that max off from the fabric), then batik fabric
give isen- isen (giving patterns in certain parts then closed by wax), then the fabric is
inserted into a second bath to soga color (brown) on the new pattern. Lastly, the
fabric which has been given soga then put in a hot tub again, washed and then dried
at a place not directly exposed to sunlight. Once dry, the fabric is folded and allowed
to stand for one night so that the fabric becomes more refined [3].
Based on observations at the Perusahaan Batik Merak Manis, Laweyan
Surakarta, Batik crafters working in a sitting position on dhingklik/chair, without
backrest made from wood. Workers sit facing the batik fabric is placed in the expanse
Taking into account the working posture assessment results used RULA and
NBM assessment methods then done the improvement process on the pencantingan
department. Observations were related to the efforts to improve working posture was
done using value engineering. Value engineering is known as an organized/
systematic approach directed at analyzing the function of systems, equipment,
facilities, services, and supplies for the purpose of achieving their essential functions
at the lowest life-cycle cost consistent with required performance, reliability, quality,
and safety [8].
II. METHOD
The design was done using the method of value engineering. This design
consists of five stages, namely the information stage, creative stage, evaluation stage,
development stage, and evaluation stage.
At the information stage was done observation to the working system and was
done identify of needs and desires of workers. Based on observations, the workers are
often complain of stiffness or cramping in the body, so that workers are seen often
using a liniment on their body that feels pain so that workers are not comfortable in
the work, and this was confirmed by the ratings of Rapid Upper Limb Assessment
and Nordic Body Map which workers are look feel complaining of pain or discomfort
while they are working. Once known issues through field study and problems
identification, then to improve the value-added of batik equipment like
dhingklik/chair and gawangan, then researcher was tried to apply value engineering
studies or value engineering, to identify the needs related to the gawangan and chairs.
At the alternatives stage was done brainstorming, and expected the alternative
idea of designs of batik work equipment of gawangan and chair based on the
identification of needs, to be developed and improved from the design of existing
equipments.
In the evaluation stage was done the analysis and evaluation of each
alternative by assessing strengths and weaknesses by some batik company owners.
At the development stage was done the development design by considering
anthropometric design, and performed an assessment of alternative manufacturing
costs.
At the recommendations stage was done the comparison of using products of
recommendation result with the existing products used the body posture analysis of
Rapid Upper Limb Assessment (RULA).
III. RESULT
A. Information Stage
According to the assessment of Rapid Upper Limb Assessment was indicated
that the workers posture was included in category score of 5, which indicated that
further investigation was needed and needed immediate repair. The next assessment
by Nordic Body Map (attached) was shown that the workers was complained of pain
in the upper body including the upper neck, nape of neck, left shoulder, right
shoulder, left upper arm, back, waist, left calf, and right calf. This was corroborated
by the workers are often used liniment on their body that feels pain.
The need identification was carried out to get information directly to the
complaints and expectations of workers that directly related to the working system
being studied. Identification was used the interview method based on the Garvin
method. In accordance to the type of work or batik drawing activity then the aspects
were studied including of performance, conformance, features, durability, and
serviceability. The need identification of workers for gawangan was shown in Table
1 below :
Dimensions of
Question
Quality
Needs
Technical Needs of
Identification
Tools Design
complaints during
batik drawing
to the anthropometry
activity?
dimensions
Required chair
to hand.
anthropometry.
2 Feature
What additional
Workers want a
features are
design which in
desirable in
gawangan be
length of fabric, or
brace or drawer so
tool?
3 Serviceability
Is the treatment
(maintenance) of
market.
The identification of the workers needs for chair was stated in the following
table.
TABLE II. IDENTIFICATION OF NEED FOR CHAIR
Dimensions of
No.
Technical Needs
Question
Statement
Quality
1
of Tools Design
Performance and
Required backrest
Conformance
complaints during
on the seat.
batik drawing
activity?
in the chair
chair.
Workers feel the
Serviceability
Is the treatment
(maintenance) of
tools maintenance
dimensions in
accordance with
anthropometry
B. Creative Stage
At this stage it was expected to appear the design alternatives of batik drawing
equipment that is gawangan and chair based on the identification of needs, and then
developed and improved based on the design of existing tools. Design alternatives of
gawangan and chairs will be outlined in a tree diagram of gawangan and tree
diagram of chair.
Dimension
In accordance
Appropriatetoto the
the anthropometry
anthropometry
Iron
Gawangan
Material
Wood
Added
Features
Appropriate to the
anthropometry
Features
Chair
C. Evaluation Stage
Evaluation stage is the stage to evaluate the alternatives that appear was
related deficiency and strength.
1. Alternative 1
Based on the identification of needs, and then designed the gawangan and
chair based on needs. In alternative 1 given gawangan design appropriate to the
anthropometry dimensions so that workers do not feel pain in the body, there is a
placemat for hand so that workers do not feel pain in the shoulder, upper arm and
forearm, as well as gawangan design is appropriate to the length of the fabric so that
the fabric does not fall to the floor. The using of iron pipe material because the
components are easily found in the market, with cheap price.
The chair design was adjusted to the anthropometric dimensions so that
workers do not feel pain in their body, given foam in the seat of the chair so workers
comfortable while working, and there is a backrest so that workers do not feel pain in
their body.
Fig.3. Alternative 1
Gawangan
Chair
Stove place
12 Labor cost
Materials
Number
Cost
Black iron pipe inch x 2.63 mm x 6 m
2
Rp 95,000.00
Super Borneo wood board 2 cm x 20 cm
3
Rp 105,000.00
x4m
Iron paint 200 gram
2
Rp 32,000.00
Brush 2 inch
1
Rp
5,000.00
Thinner liter
1
Rp 90,000.00
Meranti beam wood 6 cm x 12 cm x 4
1
Rp 80,000.00
cm
Super Borneo wood board 2 cm x 20 cm
1
Rp 35,000.00
x4m
Foam
1
Rp 20,000.00
Iron 25 x 25
1
Rp 46,000.00
L iron 4 cm x 4 cm (1 kg)
0.5
Rp
8,500.00
Super Borneo wood board 2 cm x 20 cm
1
Rp 35,000.00
x4m
Rp 150,000.00
Total Cost Rp 620,500.00
2. Alternative 2
The alternative 2 functionally is equivalent to the alternative 1. In this
alternative was given gawangan design in accordance to the anthropometric
dimensions so that workers do not feel pain in their body, there is a placement of
hand so that workers do not feel pain in the shoulder, upper arm and forearm. The
difference with the alternative 1 design is the result drawers aimed the batik fabric
results do not fallen to the floor and causing dirty, and abangan design does not too
high. The using of wood material as the main component, because it is easily found in
the market.
For the chair design was adjusted to the anthropometric dimensions so that
workers do not feel pain in their body, given foam in the seat of the chair so workers
comfortable while working, and there is a backrest so that workers do not feel pain in
their body.
Fig.4. alternative 2
Materials
Number
Cost
Super Borneo wood board 2 cm x 20 cm x 4 m
21
Rp 735,000.00
Meranti beam wood 6 cm x 12 cm x 4 cm
2
Rp 160,000.00
Hinge 4 x 3 x 2 mm
1
Rp 36,000.00
Solid cylinder iron 4,5 x 1 inch
1
Rp 13,000.00
Wood paint 1 kg
1
Rp 48,000.00
Brush
1
Rp. 5,000.00
Thinner 1 liter
1
Rp 18,000.00
Meranti beam wood 6 cm x 12 cm x 4 cm
1
Rp 80,000.00
Super Borneo wood board 2 cm x 20 cm x 4 m
1
Rp 35,000.00
Foam
1
Rp 20,000.00
Iron 25mm x 25 mm
1
Rp 46,000.00
L iron 4 cm x 4 cm (1 kg)
0.5
Rp
8,500.00
Super Borneo wood board 2 cm x 20 cm x 4 m
1
Rp 35,000.00
Rp 150,000.00
Total Cost Rp1,389,500.00
Advantages
The making cost is cheaper than
Deficiency
Rusty
alternative 2
2
Easily moved
Simple
motif
Advantages
Deficiency
Fabric was not easy dirty because it does The making cost is more expensive than
not fall to the floor
alternative 1
Susceptible to termites
D. Development Stage
From a series of analysis that has been done in the previous stage, it was
showed that seven company owners have the same opinion that choose alternative 1
as the selected alternative.
To address the issues related to the compatibility between workers and
existing work facilities on designing of gawangan and chairs for written batik is
needed anthropometric data as follows:
Information
Percentile
Objectives Application
(cm)
3 Shoulder width
4 Hips width
5 Popliteal length
6 Popliteal hight
range
8 Length of side hands
range
Information
Function
Drawer on gawangan
Clamp
Fix brace
Table
Stoves place
Wax place
Upper brace
From a series of in-depth analysis in the previous stages, it showed that the
first alternative has many advantages compared to alternative 2 in the viewing of
batik entrepreneurs.
E. Recommendations Stage
On the recommendation stage, the result of this design then was testing used
Rapid Upper Limb Assessment (RULA) methods.
Variable
Upper Arm
Observation Result
Occurs the flexion at an angle of
Score
2
42.60
2
Lower Arm
111.55
3
Wrists
3.53
4
Wrist Twist
1
3
Muscle Use
Force / Load
Neck
of 47.34
8
Trunk
of 0
9
Legs
10
Muscle Use
1
1
1
minute
11
Force / Load
The risk level has decreased from the previous, so that the design is feasible to
continue.
CONCLUSION
The highest score of the working posture on the Rapid Upper Limb
Assessment (RULA) method was obtained in pencantingan department workers is a
grand score of 5, which means that further investigation was needed and needed
immediate repair. After improving the design of gawangan and chairs, in the
pencantingan process of written batik, was adjusted using anthropometry, the results
were obtained from assessment of the selected alternative is 3, with the risk level has
decreased from the previous, so the design is feasible to continue.