Anthropometric and Geometrical Analysis to Design an Ergonomic Prototype in Jaggery (Panela) Industry

This paper presents a novel prototype, which allows the improvement of biomechanical conditions in critical process of Jaggery production. The proposed design will be selected through an ergonomic evaluation of productive process of mixing, molding and packaging. As a first step we carried out an ergonomic analysis by applying REBA postural assessment and a composed version of loads lifting NIOSH methods; afterwards clinical history was analyzed. Finally, we conducted 39 surveys to the operators belonging to the mixing, molding and packaging process. We developed a CAD model of the prototype by using the software Autodesk Inventor® and later the software Poser 8.0® was used to create a working method to link the prototype with the Colombian anthropometric data. It was found that the spatula (hand tool for mixing process) must be lengthened by 179 mm and the adjustable table should drop to 250 mm from the ground. An economic estimate was determined with a Net Present Value (NPV) of $ 7,047,110, an Internal Rate of Return (IRR) of 20.78% and a payback period of investment of 3 years. According to the results obtained by the NIOSH and REBA methods, the surveys developed and the historic information provided by the company it was possible to detect that mixing is the most critical process of Jaggery production, then was determined that modified the length of spatula and scrape the pan diagonally reduce the number of moves. Finally, the project was proven economically feasible.