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Ergonomics Improvements of the Visual Inspection Process in a Printed Circuit Assembly Factory

Yeow P. H. P., Sen R. N.

International Journal of Occupational Safety and Ergonomics

2004

Vol. 10, No. 4

369--385

An ergonomics improvement study was conducted on the visual inspection process of a printed circuit assembly (PCA) factory. The process was studied through subjective assessment and direct observation. Three problems were identified: operators’ eye problems, insufficient time for inspection and ineffective visual inspection. These problems caused a huge yearly rejection cost of US $298,240, poor quality, customer dissatisfaction and poor occupational health and safety. Ergonomics interventions were made to rectify the problems: reduced usage of a magnifying glass, the use of less glaring inspection templates, inspection of only electrically non-tested components and introduction of a visual inspection sequence. The interventions produced savings in rejection cost, reduced operators’ eye strain, headaches and watery eyes, lowered the defect percentage at customers’ sites and increased the factory’s productivity and customer satisfaction.

Ergonomic Study on the Manual Component Insertion Lines for Occupational Health and Safety Improvements

Sen R. N., Yeow P. H. P.

International Journal of Occupational Safety and Ergonomics

2003

Vol. 9, No. 1

57--74

The study aimed at reducing the occupational health and safety problems faced by the manual component insertion operators. Subjective and objective assessments, and direct observations were made in the printed circuit assembly factory. Simple and low-cost ergonomic interventions were implemented, that is, repairing chairs, reducing high workloads, assigning operators to a maximum of 2 workstations, confining machines that emitted bad smell and much noise, and providing finger work aids. The results of the interventions were reductions in operators’ work discomforts, that is, chair discomfort (by 90%), high work stress, and discomfort due to frequent change of their workstations. Their health hazards were also eliminated, that is, inhalation of toxic fumes, exposure to too much noise, and pain due to pressing sharp components.