The document presents Giorgio Sudibyo's thesis on designing an assembly fixture using ergonomic approaches. The thesis aims to identify worker postures during car engine assembly, assess them using simulation tools, and develop an alternative fixture design. It analyzes assembly processes, evaluates current and alternative fixture designs using ergonomic metrics, and concludes that a well-designed fixture can significantly reduce injury risks for workers.

1. S W I S S G E R M A N U N I V E R
S I T Y
DESIGNING AND DEVELOPING AN ASSEMBLY
FIXTURE USING ERGONOMIC APPROACH
(CASE STUDY: CAR ENGINE ASSEMBLY)
A Thesis Presentation
By
Giorgio Sudibyo
In Partial Fulfillment of the Requirements for
BACHELOR’S DEGREE
IN
INDUSTRIAL ENGINEERING
SWISS GERMAN UNIVERSITY
EduTown BSDCity
Tangerang – 15339
INDONESIA

2. S W I S S G E R M A N U N I V E R
S I T Y
18/07/16
DESIGNING AND DEVELOPING AN ASSEMBLY FIXTURE USING ERGONOMIC
APPROACH (CASE STUDY: CAR ENGINE ASSEMBLY) – GIORGIO SUDIBYO – 2
OVERVIEW
• Background
• Problem Definition
• Objectives
• Literature Review
• Methodologies
• Results and Discussion
• Conclusions and Recommendation

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BACKGROUND
Competition of manufacturers with the aim of fulfilling market
demand shows that unique techniques and approach are being
considered to optimize productivity. One of such method
involves the implementation and development of assembly
fixture. This specific assembly tool supports an assembly task
by improving worker ergonomics and generates a consistent
level of accuracy to the work
DESIGNING AND DEVELOPING AN ASSEMBLY FIXTURE USING ERGONOMIC
APPROACH (CASE STUDY: CAR ENGINE ASSEMBLY) – GIORGIO SUDIBYO –
18/07/16

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S I T Y
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PROBLEM DEFINITION
Problem Statement Hypothesis
• A proper designed assembly fixture
reduces worker posture stress
possibility
• Ergonomic score (RULA and OWAS) of
the postures analyzed are significantly
reduced by the implementation of
assembly fixture
• Assembly fixture developed in this thesis
is able to simplify the work performed by
the worker and reduce the force required
to perform the tasks
• Designing an assembly fixture without
ergonomic consideration could increase
the possibility of worker injury
• Manual material handling processes
has been one of the major causes of
worker fatigue and injury
• Designing a fixture without any
methodology increases the material
handling time
18/07/16
DESIGNING AND DEVELOPING AN ASSEMBLY FIXTURE USING ERGONOMIC
APPROACH (CASE STUDY: CAR ENGINE ASSEMBLY) – GIORGIO SUDIBYO –

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OBJECTIVES
• An assembly fixture design alternative must be provided based on the analysis of
assembly fixture implementation in car engine assembly station
• Identifying worker posture while performing car engine assembly tasks by using
ergonomic evaluation methodology in Human Jack Simulation
• Assessment of working posture performed in a car engine assembly station using
Human Jack Simulation
• Constructing an analysis on the function and components of the assembly fixture
used in car engine assembly station
18/07/16
DESIGNING AND DEVELOPING AN ASSEMBLY FIXTURE USING ERGONOMIC
APPROACH (CASE STUDY: CAR ENGINE ASSEMBLY) – GIORGIO SUDIBYO –

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THESIS FOUNDATION
A Concrete Foundation is Built to establish the key elements associated with an Assembly Fixture
“ Fixtures are to hold workpieces stable and constraint without any movement during a process” - (Hashemi, 2014)
18/07/16
DESIGNING AND DEVELOPING AN ASSEMBLY FIXTURE USING ERGONOMIC
APPROACH (CASE STUDY: CAR ENGINE ASSEMBLY) – GIORGIO SUDIBYO –

7. S W I S S G E R M A N U N I V E R
S I T Y
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METHODOLOGIES
DESIGNING AND DEVELOPING AN ASSEMBLY FIXTURE USING ERGONOMIC
APPROACH (CASE STUDY: CAR ENGINE ASSEMBLY) – GIORGIO SUDIBYO –
18/07/16
The Methodology designed for this thesis
is adapted from Spiral Model developed
by Barry Boehm
Ergonomic Evaluation methodology of
RULA and OWAS are adapted to
enhance the risk analysis phase

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Assembly Fixture Analysis
Locating Points Clamps Vice Hand Lever Base Plate
Each components in an assembly fixture performs specific function
Even though all assembly fixture may have different components, the mechanism in the respective fixture should support
each other
DESIGNING AND DEVELOPING AN ASSEMBLY FIXTURE USING ERGONOMIC
APPROACH (CASE STUDY: CAR ENGINE ASSEMBLY) – GIORGIO SUDIBYO –
18/07/16

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ASSEMBLY FIXTURE EVALUATION
Engine Drawing Illustration Assembly Fixture Drawing Illustration
Simulation
environments was
created using
illustration of the
engine and assembly
fixture
The design was
adopted from a car
engine assembly
station
18/07/16
DESIGNING AND DEVELOPING AN ASSEMBLY FIXTURE USING ERGONOMIC
APPROACH (CASE STUDY: CAR ENGINE ASSEMBLY) – GIORGIO SUDIBYO –

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CAR ENGINE ASSEMBLY PROCESS ANALYSIS
Both task are selected to represent
the capabilities of the assembly
fixture
The highlighted cell represents the
position where ergonomic
evaluation are performed and
simulated
18/07/16
DESIGNING AND DEVELOPING AN ASSEMBLY FIXTURE USING ERGONOMIC
APPROACH (CASE STUDY: CAR ENGINE ASSEMBLY) – GIORGIO SUDIBYO –

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HUMAN JACK SIMULATION REPORT
18/07/16
DESIGNING AND DEVELOPING AN ASSEMBLY FIXTURE USING ERGONOMIC
APPROACH (CASE STUDY: CAR ENGINE ASSEMBLY) – GIORGIO SUDIBYO –
The lower the ergonomic score resulted in lower negative impact on the worker posture

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ASSEMBLY FIXTURE IMPLEMENTATION ALTERNATIVE
Time (In Minutes)
Assembly Process 1 2 3 4 5 6 7 8
Assembling the power supply frame by attaching the bolts to the
rear speaker body
Assembling the Crossover board to the rear speaker body
Assembling the speaker to the front body using M2 screws for
Speaker Body A
Assembling the front and rear body of speaker A
Assembling the speaker to the front body using M2 screws for
Speaker Body B
Assembling the front and rear body of speaker B
18/07/16
DESIGNING AND DEVELOPING AN ASSEMBLY FIXTURE USING ERGONOMIC
APPROACH (CASE STUDY: CAR ENGINE ASSEMBLY) – GIORGIO SUDIBYO –
A more thorough development of the assembly fixture is performed by exploring the capability alteration
Different product characteristic drives the author to select a PC speaker as the design alternative

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CONCLUSIONS
The implementation of assembly fixture in a car engine assembly line has significantly reduced
the injury possibility during assembly tasks
The implementation of assembly fixture has reduced the posture score assessed using OWAS
method by 31%, while RULA method shows that the posture performed are cut down by 42%
Performing car engine assembly processes without the use of an assembly fixture have several
negative outcomes, especially to the trunk, arms, and neck of the worker
Unfortunately, the assembly fixture in PT. XYZ has not yet fully resolve the ergonomic of the
upper limb (the scores are still marked yellow, which means that it needs to be evaluated)
Implementation of an assembly fixture can reduce the complexity and increase accuracy by
optimizing PC speaker assembly process
18/07/16
DESIGNING AND DEVELOPING AN ASSEMBLY FIXTURE USING ERGONOMIC
APPROACH (CASE STUDY: CAR ENGINE ASSEMBLY) – GIORGIO SUDIBYO –

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RECOMMENDATION FOR FURTHER RESEARCH
18/07/16
DESIGNING AND DEVELOPING AN ASSEMBLY FIXTURE USING ERGONOMIC
APPROACH (CASE STUDY: CAR ENGINE ASSEMBLY) – GIORGIO SUDIBYO –
Exploring more capabilities of the assembly fixture by experimenting on other product
characteristics
Assessing worker postures using ergonomic evaluation methods that considers an
entire body, rather than focusing solely on the upper body part
Perform an observation to an actual PC speaker assembly line, and simulate the whole
assembly process using Human Jack Simulation
An analysis on other variant of fixtures are recommended. Machining fixtures and
inspection fixtures are comprised as typical fixtures used in factories

15. S W I S S G E R M A N U N I V E R
S I T Y
Thank You
Vielen Dank
Terima Kasih
18/07/16
DESIGNING AND DEVELOPING AN ASSEMBLY FIXTURE USING ERGONOMIC
APPROACH (CASE STUDY: CAR ENGINE ASSEMBLY) – GIORGIO SUDIBYO –
Giorgio Sudibyo
Industrial
Engineering
Batch 2012