Bahir Dar University

Bahir Dar Institute of Technology

Faculty of Mechanical and Industrial Engineering
Industrial Engineering

Internship Report

Hosting Company: EXCEL PLASTICS P.L.C

Project Title: Improving Workplace Environment and Reducing Workplace

Injuries Through Ergonomic Interventions

Prepared By: NAHOM AREGA

ID NO: 1202576

Mentor: Mrs. Meseret A.

Company Supervisor: Mr.Yemaneh Fekade

Submission Date: January 31, 2024

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Declaration
I declare that this document describes my internship experience report of my four months’
time. It is prepared on general description of my stay at EXCEL PLASTICS PLC. It has been
tried to make All the information included in this document to be free from error as much as
possible. And also, documented data from the company are included for the fact that it is
needed to prepare the project.

NAHOM AREGA ________________ ________________

Name of student Signature Date

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Acknowledgment

First and foremost, I would like to express my heartfelt gratitude to the divine for granting me
the strength and guidance to successfully complete this paper. I extend my sincere
appreciation to the entire team at EXCEL PLASTICS for their unwavering support and
assistance throughout this project. I am particularly grateful to my supervisor, Mr. Yemaneh
Fekade, whose valuable advice and extensive knowledge of the plastic manufacturing
industry proved to be immensely helpful. His encouragement and motivation pushed me to
explore new avenues and possibilities for my project.I would also like to extend a special
thanks to my mentor, Mrs. Meseret, who provided invaluable guidance and support from the
beginning to the end. Her insightful guidance and ideas greatly strengthened my project, and I
am truly grateful for her unwavering dedication.Lastly, I would like to express my deepest
appreciation to my loved ones and all those who have offered their assistance in any way.
Your encouragement, understanding, and belief in my abilities have been a constant source of
inspiration throughout this journey.

Executive Summary
Internships are a valuable opportunity to gain knowledge, skills, and experience in a specific
field while establishing important connections. During my internship at EXCEL PLASTICS
PLC, I was able to acquire the necessary experience and knowledge, which I have
summarized in this report.

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The first part of the report provides an overview of the company's history, organizational
structure, and main customers and end users. It also outlines the workflow, machinery
infrastructure, main products, and raw material sourcing regions of the company.

The second part of the report highlights the benefits and practical activities I engaged in
during my internship period.

The third part focuses on a specific project I worked on during my internship. It includes the
project's title, problem statement, objectives, and significance. The data collection,
discussion, and result analysis methods used to complete the project are also described.
Additionally, recommendations and solutions to any problems encountered during the project
are included.

The fourth part of the report offers general recommendations and conclusions based on the
project's findings. It also includes references to company documents.

Table of Contents
Declaration...............................................................................................................................................ii
Acknowledgment....................................................................................................................................iii
Executive Summary................................................................................................................................iv
List of Figures........................................................................................................................................vii

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List of Tables.........................................................................................................................................vii
List of Acronyms and Abbreviation.....................................................................................................viii
CHAPTER ONE......................................................................................................................................1
1.1 Company profile of EXCEL PLASTICS.......................................................................................1
1.2 The Main Products of EXCEL PLASTICS...................................................................................1
1.2 Main Customers of the Company..................................................................................................2
1.3 Organizational Structure of the Company.....................................................................................3
1.4 Work flow of the Company...........................................................................................................4
1.4.1 The work flow of an Injection Plastic Molding Machine.......................................................4
1.4.2 The work flow of an Extrusion Plastic Molding Machine......................................................5
1.4.3 The work flow of a Blow Plastic Molding Machine..............................................................6
CHAPTER TWO.....................................................................................................................................9
2.1 The benefits of the internship?.......................................................................................................9
In which section of the company have you been working and why?..............................................9
What type of Engineering methods, tools and techniques used?.....................................................9
What major challenges and problems faced and identified while performing work tasks?............9
What measures have taken in order to overcome these challenges and problems, etc.?...............10
What you gained in terms of improving your practical skills?......................................................10
What you gained in terms of upgrading your theoretical knowledge?..........................................10
What you gained in terms of improving your team playing skills?...............................................11
What you gained in terms of improving your leadership skills?...................................................11
What you gained in terms of understanding about work ethics issues, industrial psychology and
related issues?................................................................................................................................12
What you gained in terms of entrepreneurship skills?...................................................................12
What you gained in terms of improving your interpersonal communication skills?.....................13
Recommendation and conclusion on your internship experience?................................................13
CHAPTER THREE...............................................................................................................................14
3.1 Executive Summary.....................................................................................................................14
3.2 Problem Statement and Justification............................................................................................14
3.3 Objective......................................................................................................................................15
3.3.1 Main Objective.....................................................................................................................15
3.3.2 Specific Objectives...............................................................................................................15
3.4 Methodology................................................................................................................................15
3.5 Analysis,Result and Discussion...................................................................................................16
3.5.1 Identification and Prioritaztion of Ergonomic Hazards........................................................16
3.6 Proposed Solution........................................................................................................................24

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 3.7 Conclusion and recommendation.................................................................................................47
4. CHAPTER FOUR..............................................................................................................................48
4.1 General conclusion and Recommendation..................................................................................48
References..............................................................................................................................................49

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List of Figures
FIGURE 1.1 MAIN PRODUCTS OF EXCEL PLASTICS.............................................................................................2
FIGURE 1.2 ORGANIZATIONAL STRUCTURE OF EXCEL PLASTICS.......................................................................2
FIGURE 1. 3 FLOW PROCESS OF INJECTION MACHINE..............................................................................................2
FIGURE 1. 4 FLOW PROCESS OF EXTRUSION MACHINE...........................................................................................2
FIGURE 1.5 BLOW MOLDING STAGES.......................................................................................................................2
FIGURE 3.1 LEAKAGE OF COOLANT WATER FOR HDPE EXTRUSION MACHINE.......................................................2
FIGURE 3.2 EFFECT OF THERMAL BURN..................................................................................................................2
FIGURE 3.4 PILES OF SCRAP BLOCKING EXIT WAY..................................................................................................2
FIGURE 3.5 INDUSTRIAL TROLLEY...........................................................................................................................2
FIGURE 3.6 SPRING BASED TROLLEY.......................................................................................................................2
FIGURE 3.7 WHEEL ASSEMBLY.........................................................................................................................2
FIGURE 3.8 WHEEL.................................................................................................................................................2
FIGURE 3.9 SHAFT.................................................................................................................................................2
FIGURE 3.10 BUSH..................................................................................................................................................2
FIGURE 3.11 CLIP....................................................................................................................................................2
FIGURE 3.12 BRACKET.........................................................................................................................................2
FIGURE3.13 BOARD................................................................................................................................................2
FIGURE 3.14 HANDLE............................................................................................................................................2
FIGURE 3.15 FIXED LOWER BOLT......................................................................................................................2
FIGURE 3.16 FIXED UPPER BOLT........................................................................................................................2
FIGURE 3.17 SCISSOR SUPPORT BOLT...............................................................................................................2
FIGURE 3.18 WHEEL ATTACHING BOLT...........................................................................................................2
FIGURE 3.19 COMMON NUT.................................................................................................................................2
FIGURE 3.20 SCISSOR SUPPORT..........................................................................................................................2
FIGURE3.21 SUPPORT WHEEL.............................................................................................................................2
FIGURE 3.22 ASSEMBLY OF ERGONOMIC TROLLEY.....................................................................................2

List of Tables
TABLE 3.1 CHECK LIST............................................................................................................................2
TABLE 3.2 CHECK LIST RESULT..............................................................................................................2
TABLE 3.3 PRIORITIZATION OF HAZARDS................................................................................................2
TABLE 3.4 GUIDE LINE FOR ASSIGNING REBA SCORES..........................................................................2
TABLE 3.5 BOLT AND NUT DIMENSION...................................................................................................2
TABLE 3.6 NEW REBA RESULTS

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List of Acronyms and Abbreviation

ASTM American Society for Testing and Materials

CATIA Computer Aided Three-Dimensional Interactive Application

DIN German institute for standardization

HDPE High Density Polyethylene

ISO International Organization for Standardization

MSD musculoskeletal disorders

PPR Polypropylene Random Copolymer

PVC Polyvinyl chloride

REBA Rapid Entire Body Assessment

UPVC Unplasticized Polyvinyl chloride

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CHAPTER ONE
1.1 Company profile of EXCEL PLASTICS
EXCEL PLASTICS PLC, established in 1986 E.C, is a leading manufacturer of plastic
household and industrial containers in Ethiopia. The company started with three machines and
15-20 workers but has now grown to employ over 200 permanent workers. The company
currently has two plants located in Addis Ababa and Bishoftu city.

Over the years, EXCEL PLASTICS has invested in state-of-the-art technology to produce high-
quality UPVC and HDPE pipe products. These products have gained significant presence in the
domestic market and have been used in various development projects in the country. The
company's commitment to quality is reflected in its compliance with international standards such
as American Society for Testing and Materials (ASTM), International Organization for
Standardization (ISO), and German institute for standardization (DIN).

The company's success can be attributed to its strategic initiatives, dedication to quality, and
investment in advanced equipment such as single and twin-screw extrusion plants. These
technologies enable EXCEL PLASTICS to manufacture UPVC and HDPE pipe systems with the
highest quality standards for water distribution networks, irrigation, drainage, sewerage,
construction, telecommunication, and electrical installation systems.

EXCEL PLASTICS' products are distributed and marketed across all regions of Ethiopia. The
company has become the largest producer of UPVC and HDPE pipe products in the country. Its
success is also attributed to the support of its customers, suppliers, and stakeholders.

Overall, EXCEL PLASTICS PLC has established itself as a reliable and reputable manufacturer
of plastic pipe systems in Ethiopia. The company's commitment to quality, continuous
improvement, and compliance with international standards has contributed to its success in the
market.

1.2 The Main Products of EXCEL PLASTICS

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EXCEL PLASTICS’ products range from simple House hold equpiments to large industrial

Containers and Pipes some them are shown in Figure 1.1 below.

Households PE Pipes uPVC Pipes

PPR Pipe PVC Hose Dustbins

Chairs & Tables Paint Containers

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 Figure 1.1 Main products of EXCEL PLASTICS

1.2 Main Customers of the Company

EXCEL PLASTICS produces very high-quality plastic products hence has very high value
customers
 Addis Ababa Water and Sewage Authority (AAWSA)
 World Vision
 Save the Children
 United Nations Children's Fund (UNICEF)
 International Committee of the Red Cross (ICRC)

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1.3 Organizational Structure of the Company
The Organizational Structure of EXCEL PLASTICS is shown below in Figure 1.2 .

Figure 1.2 Organizational Structure of EXCEL PLASTICS

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1.4 Work flow of the Company
The company's work flow involves several machines used in the factory, including an
extrusion machine, blow molding machine, injection machine, crusher machine, lathe
machine, and vertical drill machine.

However, the primary machines utilized in the factory's work flow are the blow molding,
extrusion, and injection machines. Let's examine their work process.

1.4.1 The work flow of an Injection Plastic Molding Machine

Injection plastic molding is a widely used manufacturing technique for producing a wide
variety of plastic products. This process involves injecting molten plastic material into a mold
cavity under high pressure, allowing it to cool and solidify before the mold is opened and the
finished product is ejected

The work flow of an injection plastic molding machine consists of several steps. First, the
mold is securely closed and held together through clamping. Then, the raw material is sucked
from a mixer in to the hopper using a suction device. After that the plastic material is injected
into the mold cavity using a heated barrel, where the plastic resin is melted and forced into
the mold under high pressure. After injection, the plastic material needs to cool and solidify,
which is facilitated by cooling channels within the mold. The cooling time depends on the
type of plastic and complexity of the product. Finally, once the plastic has cooled and
solidified, the mold opens and the finished product is ejected from the mold cavity using
ejector pins or other mechanisms. The work flow of the Injection Plastic Molding Machine is
shown diagrammatically in Figure1.3 below.

Figure 1. 3 Flow Process of Injection Machine

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The main parts of an injection plastic molding machine include:

1. Hopper: This is where the plastic resin is loaded into the machine. The hopper feeds
the resin into the heated barrel for melting and injection.
2. Barrel and Screw: The barrel is a cylindrical chamber where the plastic resin is heated
and melted. The screw, located inside the barrel, rotates and moves forward, pushing
the molten plastic towards the mold.
3. Mold: The mold consists of two halves that come together during the clamping
process. It has a cavity that determines the shape and size of the final product.
4. Clamping Unit: The clamping unit is responsible for securely closing and holding the
mold during the injection process. It provides the necessary force to keep the mold
halves together.
5. Injection Unit: The injection unit includes the barrel, screw, and nozzle assembly. It
controls the melting, injection, and flow of the plastic material into the mold cavity.

1.4.2 The work flow of an Extrusion Plastic Molding Machine

Extrusion plastic molding is a manufacturing process that involves forcing molten plastic
material through a die to create continuous profiles of various shapes and sizes. This
technique is commonly used to produce a wide range of plastic products.

The process of an extrusion plastic molding machine consists of several steps. First, the raw
plastic material is prepared by loading it into a hopper. From there, it enters the extruder,
which consists of a heated barrel and a rotating screw. Inside the barrel, the plastic material is
heated and melted through heat and pressure. The rotating screw helps to convey the material
forward and generates heat through friction. This results in the plastic material becoming
molten. Next, the molten plastic material is forced through a die, which determines the final
shape and size of the extruded product. The molten plastic material is continuously pushed
through the die, resulting in a continuous profile or shape.

After extrusion, the newly formed plastic product needs to be cooled down and solidified.
This can be achieved through various cooling methods, such as air cooling or water cooling.
Once the product has cooled and solidified, it is cut into desired lengths or shapes using a
cutting mechanism such as a saw or knife. The work flow of the Extrusion Plastic Molding
Machine is shown diagrammatically in Figure1.4 below.

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 Figure 1. 4 Flow Process of Extrusion Machine

The main machine parts of an extrusion plastic molding machine include the hopper, barrel and screw,
die, cooling system, and cutting mechanism. The hopper is where the raw plastic material is loaded
into the machine. The barrel and screw are responsible for heating and melting the plastic material.
The die determines the final shape and size of the extruded product. The cooling system helps to cool
down and solidify the product after extrusion. Finally, the cutting mechanism is used to cut the cooled
and solidified product into desired lengths or shapes. The main machine parts of an extrusion plastic
molding machine include:

1. Hopper: Similar to an injection molding machine, the hopper is where the raw plastic material
is loaded into the machine.
2. Barrel and Screw: The barrel is a heated cylindrical chamber where the plastic material is
melted and prepared for extrusion. Inside the barrel, there is a rotating screw that helps to
convey the material forward and generate heat through friction.
3. Die: The die is a specially designed opening through which the molten plastic material is
forced to form a specific shape. It determines the final shape and size of the extruded product.
4. Cooling System: After extrusion, the product needs to be cooled down and solidified. The
cooling system can include air cooling or water-cooling methods to achieve this.
5. Cutting Mechanism: Once the product has cooled and solidified, it needs to be cut into
desired lengths or shapes. The cutting mechanism can be a saw, knife, or other cutting tools.

1.4.3 The work flow of a Blow Plastic Molding Machine

In the manufacturing sector, blow plastic molding machines are used to create hollow plastic
products like bottles, containers, and other things of a similar nature. To produce the required
shape of the product, these machines use a process known as blow molding in which molten
plastic material is expanded inside a mold.
The typical process of a blow plastic molding machine involves several stages. First, the raw
materials, usually plastic pellets or granules, are prepared by loading them into a hopper or
material feeder. The plastic material is then heated to a specific temperature to transform it
into a molten state, making it easier to mold. Once melted, the plastic material is injected into
a hollow mold cavity. The mold is typically composed of two halves that combine to form the
desired shape of the final product. In the blow molding stage, a hollow tube called a parison
is created from the molten plastic material and placed inside the mold cavity. Air is blown
into the parison, causing it to expand and conform to the shape of the mold. After the blow

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molding process, the mold is cooled to solidify the plastic and maintain its shape. The cooled
and solidified plastic product is then ejected from the mold cavity either manually or
automatically using ejector pins or air ejection systems. Any excess plastic material or flash
is trimmed off using cutting tools or blades, and finishing touches like labeling or printing
may be added. Finally, the finished products are inspected for defects or imperfections, with
defective products being discarded and acceptable ones being packaged and prepared for
distribution or further processing. This workflow ensures the production of high-quality
plastic products with consistent shapes and sizes. The work flow of the Blow Plastic Molding
Machine is shown diagrammaticaly in Figure 1.5 below.

Figure 1.5 Blow Molding Stages

The main machine parts of a blow plastic molding machine can vary depending on the
specific type of machine and product being produced. However, some common machine parts
include:

1. Hopper or material feeder: This is where the raw materials, such as plastic pellets or
granules, are loaded into the machine for processing.
2. Heating system: The heating system is responsible for heating the plastic material to a
specific temperature, typically through the use of heating elements or heaters. This
transforms the plastic into a molten state, making it easier to mold.
3. Injection system: The injection system is used to inject the molten plastic material
into the mold cavity. It typically consists of an injection nozzle or sprue, which
delivers the plastic into the mold.
4. Mold cavity: The mold cavity is where the plastic material is shaped and formed into
the desired product. It is typically composed of two halves that come together to
create the shape of the final product.
5. Parison extrusion system: In blow molding, a hollow tube called a parison is created
from the molten plastic material. The parison extrusion system is responsible for
creating and delivering the parison into the mold cavity.
6. Blow molding system: The blow molding system is used to inflate the parison with
air, causing it to expand and conform to the shape of the mold. This system typically
includes blow pins or nozzles that deliver the air into the parison.
7. Cooling system: After the blow molding process, the mold needs to be cooled to
solidify the plastic and maintain its shape. The cooling system can include water
channels or cooling plates that help dissipate heat from the mold.

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 8. Ejection system: Once the plastic has cooled and solidified, it needs to be ejected
from the mold cavity. This can be done manually or automatically using ejector pins
or air ejection systems.
9. Trimming and finishing tools: Any excess plastic material or flash that remains on the
final product after ejection is typically trimmed off using cutting tools or blades.
Finishing touches like labeling or printing may also be added to the product.

These are some of the main machine parts involved in the blow plastic molding process. The
specific type of product being produced may require additional or specialized machine parts
to achieve the desired shape and quality.

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CHAPTER TWO
2.1 The benefits of the internship?
Doing an internship was very important for gaining hands-on experience, improving
communication skills, and building self-assurance. It has also helped me to better understand
the difference between what we learn in class and what happens in real-life work situations.
Overall, the internship practice gave me a glimpse of what I can expect in my future career.

In which section of the company have you been working and why?
Since the industry I was in was a plastic manufacturing industry there weren’t that many
sections. There were Production, Maintenance and Quality inspection departments which
were related to Electrical, Mechanical, Industrial engineering but above all with Chemical
engineering. Therefore, my work primarily revolved around the production department. This
involved transportation and feeding of raw materials to machines, starting and operating the
different machines with the assistance of the professional operators, and also performing
finishing tasks on products. The finishing tasks are mainly removing remaining extensions
from the products by using Blades. Additionally I also worked with the quality inspection
department from time to time by assisiting in physical inspection.

What type of Engineering methods, tools and techniques used?

As an intern in Industrial Engineering, my primary objective was to enhance productivity by
implementing the techniques I had learned in my coursework to optimize the production
process and minimize waste. However, upon assessing the production planning, processes,
and logistics, I discovered that they were already functioning efficiently. Despite this, I
identified two problems that needed attention: machinery downtime resulting from
mechanical breakdowns or sensor failure, and ergonomic issues. Since a course in
Maintenance Engineering and Management was not Provided by our Faculty to address the
former issue, I decided to focus on the latter and utilized scientific data collection and
principles of ergonomics to improve workplace safety and employee motivation, ultimately
leading to increased productivity. Through this process I have applied different engineering
tools and techniques. For example, I have applied the process of Primary data collection
through observation and check lists. I have made a risk assessment which assisted in
prioritization of Hazards by considering severity, number of workers in which it affects, and
likelihood of the hazard happening. Also I have used the REBA equation (Rapid Entire Body
Assessment) to check the severity of a high priority hazard. Lastly I have used CATIA
software to design an Ergonomic Trolley.

What major challenges and problems faced and identified while performing work tasks?
EXCEL PLASTICS is a prominent plastic company in Ethiopia that has machinery requiring
minimal technical intervention beyond maintenance and cleaning, this minimized my chance
to practice more technical activities. Despite that I tried to get some technical knowledge
through observation and assistance during maintainace and also how to operate some of the
macines. Additionally, I felt uneasy due to the absence of safety shoes and gloves and other
Ergonomic Problems, impeding my ability to perform various tasks. The lack of Wi-Fi access

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hindered my learning progress, making it difficult to acquire new knowledge on sight when I
faced new concepts. Furthermore, the company lacked an on-site Cafeteria, posing a
challenge during lunchtime. Lastly, the company was bisected by a road, requiring me to
cross it frequently to access different areas of the company.

What measures have taken in order to overcome these challenges and problems, etc.?
To address the aforementioned challenges, I took proactive measures as most of them were
beyond my control. To improve my technical skills, I sought guidance from friendly
colleagues who showed me how to operate various machinery. Additionally, I participated in
maintenance activities to gain a better understanding of how the machines functioned. I also
helped with cleaning, inspecting product quality, and performing finishing tasks where
possible.

Regarding the lack of Wi-Fi access, I realized that it was intentionally restricted to ensure
workers remained focused on their tasks. Therefore, I found alternative sources of access to
enhance my learning experience. As for the absence of an on-site eatery due to space
limitations, I had to rely on external options.

The company's division by a busy road was a major concern, but constructing a bridge
between the two sections was deemed too expensive. Therefore, I developed my own system
of alternating between the two sections to minimize the risk of crossing the road frequently.

Lastly, I aimed to improve ergonomic conditions by creating an Ergo-scan project. Despite

the challenges, I remained determined to overcome them and make the most of my time at
EXCEL PLASTICS.

What you gained in terms of improving your practical skills?

Throughout my time in the internship program, I was fortunate enough to acquire a wealth of
practical knowledge that will undoubtedly serve me well in my future endeavors. The
employees at EXCEL PLASTICS were incredibly generous with their time and expertise,
patiently showing me the ins and outs of operating various types of machinery. Additionally,
I was able to gain a comprehensive understanding of the company's methods for arranging
products, inspecting goods, and monitoring the activities of machines. Perhaps most
excitingly, I was able to hone my skills in performing finishing tasks on a variety of products,
including jerry cans, plastic chairs, and paint buckets. Overall, this internship was an
invaluable learning experience that has left me feeling confident and capable as I move
forward in my career.

What you gained in terms of upgrading your theoretical knowledge?

During my internship at EXCEL PLASTICS, I was able to acquire a lot of theoretical
knowledge that pertains to my Ergo scan project as well as the plastic industry as a whole.
One of the most valuable insights that I gained was a deeper appreciation for the importance
of ergonomics in real-life situations. Having worked in an unsafe environment myself, I came
to realize just how much the principles of ergonomics can improve workplace safety and
efficiency.

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In addition to this, I also gained a better understanding of various plastic materials, including
what they are made from and their unique properties. This knowledge has proven to be
incredibly useful when it comes to product design, material selection, and quality control.

Furthermore, I was able to explore deeper into the manufacturing processes involved in the
plastic industry, including injection molding, blow molding, and extrusion manufacturing.
This has given me a greater appreciation for the complexity of these processes and how they
can be optimized to achieve better results. Finally, my internship experience also highlighted
the seriousness of safety regulations within the plastic industry. Given the inherent risks
involved in working with plastics, it is essential that companies take appropriate measures to
ensure the safety of their employees and comply with relevant regulations.

What you gained in terms of improving your team playing skills?

Embarking on this internship journey alone was initially a daunting experience for me. I
found myself working independently and not having the opportunity to exercise my team
playing skills with my classmates. However, this experience taught me the value of
collaboration and how it can greatly benefit one's work. As I struggled to piece together my
internship report and project, I realized that I needed the support and input of others to
achieve my goals.

Despite being alone in this internship, I was able to build my confidence by making new
friends within the company who were older and more experienced than me. Through these
interactions, I learned the importance of active listening and being attentive to others when
exchanging ideas or having conversations. I also discovered the power of helping and
cooperating with people, even if it means sharing small pieces of knowledge.

Most importantly, I learned to accept advice and technical support from those around me.
This allowed me to grow both personally and professionally, and I now understand the
significance of working collaboratively in achieving success. In summary, my solo internship
experience taught me valuable lessons about teamwork, communication, and the importance
of building relationships in the workplace.

What you gained in terms of improving your leadership skills?

During my internship, I had the opportunity to work independently, which initially made me
feel apprehensive about my ability to succeed. However, this experience taught me the
importance of collaboration and the benefits it can bring to one's work. One of the most
significant aspects of my internship was the opportunity to learn from experienced
individuals such as the production manager, Mr. Yemaneh, and several shift leaders. Here are
some of the valuable lessons I learned from them:

 Leading by example: All of these individuals were sharp in their scheduling and
active in their work. They demonstrated that leadership is not just about telling others
what to do but also about showing them how to do it.
 Effective communication: They emphasized the importance of communicating with
workers at all levels and ensuring that everyone is on the same page.

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  Planning and scheduling: They showed me how to plan, prepare, and schedule for
different activities to make every plan achievable.
 Building self-confidence: Working with these individuals helped me build my
confidence and believe in myself.
 Eliminating fear and doubt: They taught me how to eliminate excess fear and doubt
and focus on achieving my goals.
 Developing technical skills: I learned how to develop technical skills that help
understand and solve problems.
 Motivating others: They showed me how to motivate and help others develop, which
is a key aspect of effective leadership.

In summary, my internship experience taught me valuable lessons about teamwork,

communication, planning, self-confidence, technical skills, and motivation. I am grateful for
the opportunity to learn from experienced individuals who helped me grow both personally
and professionally.

What you gained in terms of understanding about work ethics issues, industrial
psychology and related issues?
Overall, my internship experience at EXCEL PLASTICS has taught me valuable lessons
about work ethics, industrial psychology, and related issues. I have learned that a strong work
ethic is essential for success in any profession and that it encompasses a range of attitudes,
behaviors, and interactions with others. I have also gained a better understanding of industrial
psychology and how it can be applied to optimize human resources in the workplace.

Through my internship, I have developed problem-solving skills, improved communication

and teamwork abilities, and gained practical experience through training. I have also learned
the importance of respecting rules and regulations, being accountable and responsible,
building positive relationships with colleagues, and maintaining a positive outlook. These
qualities are crucial for contributing to a productive and successful workplace.

In conclusion, my internship experience has been invaluable in helping me grow both

personally and professionally. I am grateful for the opportunity to have worked at EXCEL
PLASTICS and for the lessons I have learned about work ethics, industrial psychology, and
related issues. I am confident that these lessons will serve me well in my future endeavors.

What you gained in terms of entrepreneurship skills?

My internship experience at EXCEL PLASTICS has given me a deep understanding of the
importance of entrepreneurship in driving economic growth and creating job opportunities.
Through this program, I have learned about the entire process of entrepreneurship, from
identifying issues to developing solutions that create jobs and career possibilities for
individuals. This experience has also taught me how to address industry challenges and cut
costs by developing innovative solutions.

Throughout this internship, I have gained valuable entrepreneurship skills, including

leadership, risk-taking, market analysis, resource management, innovation, risk management,
goal-setting, decision-making, time management, teamwork, planning, coordination,

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organization, creativity, and adaptability. Additionally, this experience has instilled in me a
strong desire to become a successful entrepreneur, as well as self-confidence, optimism, a
positive response to challenges, and a thirst for new information and technologies.

Overall, my internship at EXCEL PLASTICS has been an incredible opportunity to learn

about entrepreneurship and gain valuable skills that will serve me well in my future career
endeavors.

What you gained in terms of improving your interpersonal communication skills?

During my internship at EXCEL PLASTIC, I significantly improved my interpersonal
communication skills. This experience allowed me to engage with a diverse group of
individuals both within and outside of the workplace. By interacting with colleagues, fellow
interns, and friends from various universities, I realized the importance of effective
communication in achieving success in a collaborative production environment. As a result, I
made a conscious effort to enhance my communication skills, which helped me motivate
others, foster problem-solving, build trust, facilitate negotiations, promote integrity, and
manage conflicts. Overall, my internship provided me with valuable communication skills
that will benefit me both professionally and personally.

Recommendation and conclusion on your internship experience?

My internship at EXCEL PLASTIC was an incredible learning experience that helped me
develop my communication skills in a variety of ways. The company's emphasis on
teamwork and communication allowed me to gain valuable experience in motivating others,
building trust, and promoting integrity. I believe that these skills will serve me well in my
future career, and I am grateful for the opportunity to have worked with such a talented and
diverse group of individuals.

As a trainee, I also had the opportunity to observe the production process at EXCEL
PLASTIC and identify areas for improvement. I recommend that the factory implement new
mechanisms for material handling, maintain cleanliness in the production area, and take
action to reduce the distance that scrapped materials need to travel. Additionally, I
recommend that the factory provides a cafeteria for workers to have their meals.

Overall, my internship at EXCEL PLASTIC was an excellent opportunity to apply the

theoretical knowledge gained in university courses in a practical setting. I highly recommend
this internship to other university students looking to gain valuable experience in the plastic
production industry.

14
CHAPTER THREE
3.1 Executive Summary
The following Project provides the identification, prioritization and Improvement solution of
Ergonomic Hazards at EXCEL PLASTICS PLC. Primarly seven of the most common
Hazards in plastic industries were selected which are Ergonomic Hazards, Environmental
Hazards, Physical Injuries, Thermal Burns, Fire and Explosion Hazards, Noise Pollution and lastly
Chemical Exposure. Then by using a Check List and a thorough observation of the company it was
identified that out of the seven Hazards, Five were found to exist, one was difficult to
determine and only one major Hazard did not exist. This showed that there are several
Ergonomic related problems that really need to be addressed.

With in the major Hazards existed specific Hazards that needed to be prioritized in order to
address the one which was more urgent. The Prioritization of the Hazards was carried out by
considering three factors, Severity of Hazard, Likelihood and Number of workers it would
affect if it were to happen. Accordingly the exisiting hazards were prioritized as High,
Medium and Low Priority Hazards. The details of the prioritization are presented in Table
3.3.

Hazard related to Lifting and Carrying or loading and unloading was found to be a High
Priority. To be sure that this Hazard is really High Priority and also to evaluate the results that
could be achived from the solution, the REBA equation was applied. Hence an Ergonomic
Trolley with a spring support was found to be a better improvement solution. The proposed
solution was able to reduce the first REBA score which was 128 down to 16. Although the
result was not with in the ideal range, The achievement can serve as a stepping stone for
future improvments.

In summary an Ergonomic assessemnet and design was ws applied to create a safe and better
working environment at EXCEL PLASTICS.

3.2 Problem Statement and Justification

During my internship at EXCEL PLASTICS PLC, I noticed that there are ergonomic hazards
in the workplace that put employees' health and safety at risk. These hazards can lead to
work-related injuries and illnesses, resulting in lower productivity, more absences, and higher
healthcare costs. This project aims to identify and assess these hazards, prioritize them, and
develop strategies to make the workplace safer and healthier.
It's important to address ergonomic hazards because they directly affect employees' well-
being. By reducing these hazards, we can prevent injuries and illnesses, keeping employees
physically safe.Improving workplace safety has other benefits too. It reduces the number of
accidents and injuries, leading to fewer absences and higher productivity. This saves money
on healthcare costs for both employees and the company.Creating a safer workplace also
improves job satisfaction and performance. When employees feel safe and comfortable, they
15
are happier and more motivated. Prioritizing ergonomic principles fosters a positive work
culture and may reduce employee turnover.
In conclusion, the presence of ergonomic hazards at EXCEL PLASTICS PLC poses risks to
employees' health and safety. By addressing these hazards, we can create a safer workplace,
prevent injuries and illnesses, increase productivity, and save on healthcare costs. Improving
employee well-being and job satisfaction is also a positive outcome. Therefore, it is important
to take action and make the workplace safer and healthier for the benefit of everyone
involved.

3.3 Objective
3.3.1 Main Objective
The main objective of this ergonomic project is to improve the workplace environment and
reduce the risk of work-related injuries and illnesses in EXCEL PLASTICS PLC by
implementing ergonomic principles.

3.3.2 Specific Objectives

 To identify and assess ergonomic hazards in the Factory.
 To prioritize existing Hazards
 To develop and implement strategies to eliminate or reduce ergonomic hazards.

3.4 Methodology
1. Identify and assess common ergonomic hazards that exist in Plastic Industries.

I have found that the following are the most common ergonomic hazards that exist in Plastic
Industries
 Ergonomics Hazards
 Physical Injuries
 Environmental Hazards
 Noise Pollution
 Thermal Burns
 Chemical Exposure
 Fire and Explosion Hazards
2. Prepare a Check List to help identify those hazards that exist in case company.
Accordingly, the Check List under Table 3.1 was prepared
Table 3.1 Check List

NO. Common Hazards in Plastic Existence of these Hazards in EXCEL PLASTICS

Industries PLC

Yes, it does No, it doesn’t Difficult to

Decide

1 Ergonomic Hazards

2 Environmental Hazards

16
 3 Physical Injuries

4 Thermal Burns

5 Noise Pollution

6 Fire and Explosion Hazards

7 Chemical Exposure

3. After careful consideration of the existing factors, select the best method to collect data
and conduct data collection.
As the factory is relatively small in size, I have opted to gather primary data through the
method of observation for data collection.
4. Analyze data to determine which hazards are more significant and prioritize them for
action using Engineering Methods
5. Develop an Engineering Solution to eliminate or reduce the Ergonomic Hazard

3.5 Analysis,Result and Discussion

3.5.1 Identification and Prioritaztion of Ergonomic Hazards
Over the course of more than two months, I conducted a thorough observation of both the
Factory A and B sections of the company to identify the existing Hazards. This resulted in the
compilation of a Checklist, which I will now discuss in detail to explain the presence of each
hazard. Additionally, I will relate my findings back to the objectives of my project and offer
recommendations for further action or research. The Hazards that were identified are
presented in Table 3.2 below.

Table 3.2 Check List Result

NO. Common Hazards in Plastic Existence of these Hazards in Excel

Industries Plastics PLC

Yes, it does No, it doesn’t Difficult to

Decide

1 Ergonomic Hazards 
2 Environmental Hazards 
3 Physical Injuries 
4 Thermal Burns 
5 Noise Pollution 

17
 6 Fire and Explosion Hazards 
7 Chemical Exposure 

Ergonomic Hazards
Workers in plastic manufacturing often perform repetitive tasks that can cause
musculoskeletal disorders such as carpal tunnel syndrome, tendinitis, and back pain. The
production process can also require workers to work in awkward positions or confined
spaces, leading to injuries.
So, these Hazards were mainly observed through the following tasks
During unloading of Raw materials and Loading finished Products: The use of improper
lifting methods and the reliance on shoulders for carrying heavy raw materials during
unloading can pose a significant risk to the musculoskeletal health of workers. This is due to
the repetitive strain and overexertion that can occur, leading to the development of serious
conditions such as rotator cuff injuries, shoulder impingement syndrome, and tendonitis. Now
a single packed Raw material weighs 25Kgs which is already a significant load. During my
observation I have seen that a single person carries about five packs on their shoulder which
adds up to 125 kgs. Furthermore, the storage of raw materials in a distant location within the
company only adds to the hazards and risks involved in carrying such heavy loads. A similar
hazardous activity is observed during loading of finished products on to Trucks.
During feeding of Mixers with Master batch and Raw materials: During the process of
feeding mixers with master batch and raw materials, I have observed that workers engage in
repetitive and improper lifting of heavy materials. This can result in back pains and
musculoskeletal disorders (MSD).

Physical Injuries
The manufacturing process involves the use of heavy machinery and equipment, which can
cause physical injuries such as cuts, bruises, and fractures. Workers can also be injured due to
the improper handling of materials, slips, and falls.
Mainly two reasons may contribute adversely for physical injuries in this factory, The first
one is
Leakage of coolant water from the HDPE extrusion machine
The leakage of coolant water from the HDPE extrusion machine can cause physical injury in
several ways, making it hazardous ergonomically. Firstly, the coolant water can make the
floor slippery, increasing the risk of slip and fall accidents for workers. This can lead to
injuries such as sprains, fractures, and head injuries.
Secondly, if the coolant water comes into contact with electrical equipment or wiring, it can
cause electrical shocks to workers, which can be fatal. Thirdly, the coolant water may contain

18
chemicals or contaminants that can cause skin irritation, respiratory problems, or other health
issues if workers come into contact with it.
Furthermore, the leakage of coolant water can also impact the ergonomics of the workplace.
Workers may have to bend or crouch to avoid the wet areas, leading to discomfort and strain
on their muscles and joints. This can result in musculoskeletal disorders such as back pain,
neck pain, and repetitive strain injuries.
In summary, the leakage of coolant water from the HDPE extrusion machine can pose
significant hazards to workers in a plastic factory. It can cause physical injuries, impact the
health of workers, and affect the ergonomics of the workplace. Therefore, it is essential to
address this issue promptly to ensure a safe and healthy work environment for all employees.
The Leakage of the coolant water can be obsereved in the Figure 3.1 below.

Figure 3.1 Leakage of coolant water for HDPE Extrusion Machine

Lack of Safety shoes for most workers

The lack of safety shoes for most workers in the plastic factory can exacerbate the hazards
posed by the coolant water leakage from the HDPE extrusion machine. Without proper
footwear, workers are at an increased risk of slipping and falling on the wet floors, which can
result in injuries such as sprains, fractures, and head injuries.
Moreover, the absence of safety shoes can also lead to foot injuries if workers come into
contact with sharp or heavy objects on the factory floor. This can cause cuts, bruises, and
even amputations, depending on the severity of the injury.
In summary, the absence of safety shoes for most workers in the plastic factory adds to the
hazardous and ergonomically scientific nature of the coolant water leakage from the HDPE
extrusion machine. It increases the risk of slip and fall accidents, foot injuries, and
musculoskeletal disorders, highlighting the importance of providing appropriate personal
protective equipment to ensure a safe and healthy work environment.

Environmental Hazards

19
Plastic manufacturing can also have significant environmental hazards. The production
process generates a lot of waste, including hazardous waste that can harm the environment.
Improper disposal of this waste can lead to soil and water contamination, air pollution, and
other environmental problems.
On this case EXCEL PLASTICS is exceptional since it has its own waste recycling process.
Through it, scrap and defective products are not only prevented from ending up in landfills
but are also transformed into new, usable products. This innovative approach not only
reduces waste but also conserves resources and minimizes the carbon footprint of the
company. EXCEL PLASTICS sets a great example for other companies in the industry to
follow in adopting environmentally-friendly practices.

Noise Pollution
The production process in plastic manufacturing involves the use of heavy machinery that
can create a lot of noise. Exposure to loud noise for extended periods can lead to hearing loss,
tinnitus, and other health problems.
In order for noise levels to be considered hazardous, their intensity must exceed 90 decibels.
To accurately measure this intensity, specialized scientific equipment known as a sound level
meter is required. As I was unable to obtain this equipment, I have listed its inclusion on the
checklist as a challenging task in determining hazardous noise levels.

Thermal Burns
The production process also involves the use of hot machines and materials that can cause
thermal burns. Workers can be injured if they come in contact with hot surfaces, hot liquids,
or molten plastic.
More or less most machines have protected region to avoid burns, But the operation of blow
mold machines poses a significant hazard to workers. Specifically, tasks involving the
removal of extended parts from the finished product or the removal of resin from the machine
are particularly hazardous. The lack of proper protective gloves exacerbates this risk, as many
workers are forced to handle hot materials with their bare hands. This continuous exposure to
high temperatures can lead to severe burns and other thermal injuries. The temperature of the
resin can reach levels that are extremely dangerous, with temperatures exceeding 200 ℃. The
Effect of a thermal burn could be so severe it can even hospitalize workers. Its effects can be
seen in Figure 3.2 below.

20
 Figure 3.2 Effect of Thermal Burn

Chemical Exposure
One of the most significant hazards in plastic manufacturing is chemical exposure. The
production process involves the use of many hazardous chemicals, such as solvents,
adhesives, and resins, that can cause harm to workers if not handled properly. Exposure to
these chemicals can lead to serious health problems such as skin irritation, respiratory issues,
and even cancer.
One of the unique features of EXCEL PLASTICS is that it fully uses pure raw material for its
products. And these raw materials are provided by Saudi Arabia's Basic Industries
Corporation or commonly known as SABIC. The use of SABIC plastic raw materials in
plastic factories can pose health risks to workers if proper safety measures are not taken.
Exposure to hazardous chemicals such as styrene, benzene, and vinyl chloride can cause
respiratory problems, skin irritation, and other health issues. During the processing of these
materials, fumes may be released, which can lead to respiratory problems if inhaled, with in
Excel plastic Factory One there are eight large machineries comparatively the ventilation
system is inadequate specially when all machines are working simultaneously. Workers may
also come in contact with the raw materials, causing skin irritation, rashes, and other skin-
related health issues. Exposure to SABIC plastic raw materials can also cause eye irritation,
leading to vision problems and other eye-related health issues.

Fire and Explosion Hazards

Plastic manufacturing also involves the use of flammable chemicals that can ignite and cause
explosions if not handled properly. Sparks or static electricity can also cause fires in areas
where flammable materials are present. The risk of fire and explosion is especially high in
areas where chemicals are stored or transported.
The hazards of fire and explosions are not only closely related to the causes of fire, but also
to the handling and mechanisms used to deal with them, as well as the design and
maintenance of the facility to prevent such hazards. At EXCEL PLASTICS, finished products
are stored throughout the manufacturing area until taken by customers, blocking aisle ways
and requiring workers to cross over them for passage. This is clearly shown in Figure 3.3
below.

21
 Figure 3.3 Finished Products blocking Aisle way

Additionally, scrap materials are stored at the entrance of factory one, blocking the exit gate
until they are taken to factory two for processing. In addition to that there is only a single exit
for factory one. While seemingly harmless during normal operations, these actions pose a
significant hazard in the event of a fire or explosion, making it impossible to escape and
increasing the danger significantly. This can be shown in Figure 3.4 below.

Figure 3.4 Piles of Scrap Blocking Exit way

Now since the existing hazards have been identified clearly Prioritization can follow.To
prioritize the existing hazards personal experience is more useful but additionally these
factors are needed to be considered to make a good risk assesement
 Severity: If the hazard leads to an incident, how serious might the resulting injury or
illness be?
 Likelihood: How likely is an incident to occur? This could be influenced by how
often an activity is done, how often workers are exposed, and how close workers are
to the hazard.

22
  Number of workers: How many workers are exposed to the hazard ?

Accordingly the prioritization of the Hazards is presented in Table 3.3 below.

Table 3.3 Prioritization of Hazards

NO. Hazard Severity Likelihood Number of Priority for

(High. Medium, (high. medium, Workers Action
Low) low)) exposed (high.
medium,
low)

1. Improper lifting and H H 15-20 H

carrying
(Loading/Unloading)

2. Leakage of coolant water H L 5-10 M

from the HDPE extrusion
machine

3. Lack of Safety Shoes M M 5-10 M

4. Lack of Protective L M 4-6 L

Gloves

5. Lack of adequate H M 15-25 M

ventilation

6. Lack of storage for H L 15-30 M

finished products

7. Lack of multiple H L 15-30 M

Emergency Exits

Now since the most prioritized Hazard is Improper Lifting and Carrying, I used the Rapid
Entire Body Assessment Equation, also known as the REBA equation. This because although
the Hazard is High Priority, The seriousness should be assessed first.
REBA is a method used to evaluate, assess and improve the ergonomics of tasks that involve
repetitive or forceful movements, awkward postures, and other physical stressors that may
contribute to musculoskeletal disorders.

Accordingly, here is the commonly used guideline for assigning scores in the REBA
equation, presented in Table 3.4 below.

Table 3.4 Guide Line for assigning REBA scores

Neck position (N): Trunk position (T): Leg position (L):

23
1: Neutral or relaxed position 1: Upright or slightly bent 1: Neutral or relaxed position

2: Slightly bent or rotated 2: Bent forward or sideways 2: Slightly flexed or extended

slightly
3: Bent or rotated moderately 3: Moderately flexed or
3: Bent forward or sideways extended
4: Bent or rotated significantly moderately
4: Significantly flexed or
4: Bent forward or sideways extended
significantly

Force Analysis: Arm position (A): Coupling Analysis:

- Force exertion (F): - 1: Neutral or relaxed - Coupling (C):

position
- 1: Very light force - 1: Simple or static coupling
- 2: Slightly raised or lowered
- 2: Light force - 2: Limited multi-limb or
- 3: Moderately raised or trunk involvement
- 3: Moderate force lowered
- 3: Moderate multi-limb or
- 4: High force - 4: Significantly raised or trunk involvement
- 5: Very high force lowered
- 4: Complex or dynamic
coupling

Duration Analysis:

- Duration of task (D):

- 1: Very short duration

(seconds)

- 2: Short duration (minutes)

- 3: Moderate duration (10-30

minutes)

- 4: Long duration (30-60

minutes)

- 5: Very long duration (more

than 60 minutes)

24
The REBA score is classified as low, medium, or high risk based on the range it falls in
which is
 Low risk: REBA score below 4
 Medium risk: REBA score between 4 and 7
 High risk: REBA score above 7

Now, I will multiply the scores I have given for each component according to my
observation:

2 (N) x 2 (T) x 2 (L) x 2 (A) x 2 (F) x 2 (D) x 2 (C) = 128

The final REBA score is 128. Based on the REBA scoring scale, a score of 128 indicates a
high level of ergonomic risk. Therefore, immediate ergonomic interventions should be
considered to reduce the risk of musculoskeletal disorders associated with this task.
3.6 Proposed Solution
In this section it is tried to solve the exisiting High priority Ergonomic Hazard at EXCEL
PLASTICS.The currently used trolley in the company is an ordinary industrial trolley just as
the one shown in Figure 3.5. So this design assists in transporation of materials but its
assistance in material handling (loading and unloading ) is poor, which is endangering the
sfatey of workers. So I propose to design a new trolley that can assist in both transportation
and Handling of materials. In order to design the new trolley there are some design
considerations that need to be discussed.

Figure 3.5 Industrial Trolley

Swivel Caster Wheel

A swivel caster wheel is a type of wheel commonly used in trolleys and carts that allows for
easy maneuverability. It is designed to rotate 360 degrees around a vertical axis, enabling the
trolley to change direction smoothly. Based on the weight of 450 kg and the need for each
caster wheel to carry 112.5 kg, a larger diameter would distribute the weight more evenly and
reduce the risk of damage to the surface. Assuming a load capacity of 112.5 kg per caster
wheel, a suitable diameter could be around 15-20 cm. Hence, I have chosen for 15cm.

we can calculate the required width of the wheel and the size of the hole as follows:

25
1. Determine the surface area of the wheel needed to support the load:

Surface area = Load / Pressure

Pressure = Load / (π x (Diameter/2)^2)

where π is approximately 3.14, and Diameter is in meters

Plugging in the given values, we get:

Pressure = 4500 / (3.14 x (0.15/2) ^2) = 305,785 Pa

Surface area = 4500/ 305,785 = 0.0147 m^2

2. Calculate the required width of the wheel:

Assuming a cylindrical shape for the wheel, its volume would be:

Volume = Surface area x Width

Width = Volume / Surface area

Plugging in the calculated surface area and assuming a reasonable thickness of 5 cm, we get:

Width = (0.0147 x 0.05) / 0.0147 = 5 cm

Therefore, the required width of the wheel is 5 cm.

3. Determine the size of the hole:

Assuming a bolt diameter of 10 mm, we can use a standard clearance hole size of about 11
mm to allow for easy installation and movement of the caster wheel.

Spring

A spring is a mechanical device typically made of elastic materials, such as metal, that has
the ability to store and release mechanical energy. For this design I will be using a
compression helical spring as it can bear axial loads and provide resistance against
compression forces. It can also support and stabilize the weight of the trolley and its contents.
While using a spring Calculator Sites and assigning required information a suitable spring
dimension was acquired.

 Free length: 73 cm
 Solid length: 20 cm
 Spring stiffness: 76.92 N/cm
 Material type: Steel or steel alloy
 Inner diameter: 17 cm
 Outer diameter: 20 cm
 Pitch: 6cm

Board

26
The board in a trolley serves as a platform or surface that provides support for the weight of
the items or materials being transported. It is typically a flat, rigid component that spans the
width and length of the trolley's frame.

The purpose of the board in a trolley is to create a stable and secure surface for placing and
carrying various objects. For this Design the following dimensions of the board are chosen:

Length = 126cm

Width = 90cm

Height = 6cm

Frame (Base)

The frame of a trolley refers to the structural framework that provides support, stability, and
rigidity to the trolley's overall structure. It is typically made of durable materials such as
metal, steel, or aluminum and is designed to withstand the weight and stresses encountered
during transportation. And for this specific project it also holds the platform for placing the
spring and also the handle to operate the trolley.

The frame over all has the following dimension:

Height=8cm

Length=130cm

Width=90cm

Shaft height (for supporting the spring) = 16cm

Handle Length = 76cm

Handle Diameter = 86cm

Bolt and Nuts

A bolt is a threaded fastener with a head at one end and a threaded shaft at the other. A nut is
a small, usually hexagonal-shaped component with an internally threaded hole. They work
together to fasten or join two or more components together securely. For this Design multiple
bolts were designed. These details are presented in Table 3.5 below.

Table 2.5 Bolt and Nut Dimension

No. Name Bolt Material Diameter Length (including Nut Size

Type/Standard head) Pitch
(Width Across
Flats)

27
 1 Wheel Hex bolt/ISO Steel M12 120mm 19mm
Attaching Bolt 4014

2 Support Bolt Hex bolt/ISO Steel M12 90mm 19mm

4014

3 Fixed Support Hex bolt/ISO Steel M14 150mm 22mm

Bolt 4014

4 Wheel Shaft Hex bolt/ISO Steel M6 65mm 10mm

4017

Bush (Wheel Bush)

A bush, also known as a bushing or a sleeve bearing, is a cylindrical component that is used
in various mechanical applications, including wheels. The purpose of a bush in a wheel for a
trolley is to provide support, reduce friction, and facilitate smooth rotation of the wheel. Here
is the dimension of the bush:

Inner Diameter (ID)= 6.2mm

Outer Diameter (OD)= 10.9mm

Length= 50mm

Scissor Support

A scissor support, also known as a scissor lift mechanism, is a mechanical device commonly
found in spring-based trolleys or carts. It consists of a set of connected arms or links that can
be extended or compressed in a scissor-like manner. The purpose of a scissor support in a spring-
based trolley is to provide vertical lifting or lowering capabilities and stabilize the load. Here is the
dimension of the Scissor Support:

Length= 110cm

Diameter for Frame Attachment Hole = 14.5mm

Diameter for Interconnection Hole=12mm

The scissor support also exhibits a strategically positioned final indent of 20 mm on one side.
This purposeful indentation serves as a precise attachment point for seamlessly affixing a
support wheel.

These support wheels are affixed to the scissor support in order to ensure seamless sliding
within the embedded track or guidance system on both the trolley frame and board. As the
trolley board lowers or rises, the casters facilitate smooth and controlled movement along the

28
designated track, allowing for precise and effortless navigation. Here is the dimension of the
support wheel:

Outer Diameter= 30mm

Inner Diameter= 3mm

Width= 20mm

wheel covers (Brackets)

The brackets covering trolley wheels commonly referred to as wheel guards serve a specific
purpose in the functionality and safety of the trolley. Also, another primary purposes of wheel
covers is to enhance the visual appearance of the trolley. Here is the dimension of the support
Wheel:

Diameter (Distance from one edge to the opposite edge) = 55mm

Length (Depth)= 117mm

Also, the wheel cover features a precise 67° angular cut, meticulously designed to provide
optimal functionality and aesthetic appeal. Additionally, it incorporates an 11mm key hole
positioned at the narrow end, allowing for seamless attachment and secure fastening.

So the manual handling process at EXCEL PLASTICS has been identified as a significant
safety concern, particularly during the transfer of raw materials and accessory items for
machinery. One specific area of focus is the feeding of raw materials into mixers, where the
height can reach up to 1 meter and slightly above. A thorough evaluation of the hazards
involved was conducted, utilizing the Rapid Entire Body Assessment (REBA) method. The
calculated REBA value of 128 indicated a high level of risk.

So now, the new expected results of the REBA assessment, along with a comprehensive force
analysis of the trolley used for material transfer will be presented.But before that the design
result created using CATIA V5 software is shown below in Figure 3.6.. The design
incorporates several key features to enhance functionality and ease of use.

29
 Figure 3.6 Spring Based Trolley

One notable aspect of the design is the inclusion of four swivel wheels. These wheels enable
smooth maneuverability and effortless direction changes. Additionally, a spring support
mechanism is situated in the middle, serving as a pivotal feature. This unique element allows
the support board to rise when subjected to lighter weights and lower when encountering
heavier loads. Moreover, a scissor support mechanism is incorporated to prevent any
excessive bulkiness and ensure a seamless rising and lowering experience.

To accommodate the handling of heavier loads, a sturdy handle is positioned at the back of
the trolley. This placement is preferred as it minimizes the risk of back problems by
promoting pushing rather than pulling.

The implemented design successfully addresses the safety concerns related to manual
handling at EXCEL PLASTICS. It offers improved mobility, efficient weight management,
and ergonomic considerations, all aimed at enhancing the overall user experience while
ensuring the safety and well-being of employees. The following sections will provide further
details on the design features and their impact on hazard reduction and work efficiency.

Now, let us move forward to the anticipated results of the REBA assessment and make a
clear comparison with the previous findings. This will allow us to discern the evident changes
that have taken place. The new Reba results are summarized under Table 3.6.

Table 3.6 New REBA Results

Body Posture Elements Previous Observation Anticipated Results

Neck Position 2 2

Trunk Position * 2 1

Leg Position 2 2

Arm Position * 2 1

30
 Force Analysis * 2 1

Duration Analysis 2 2

Coupling Analysis 2 2

Final REBA Score 128 16

As you can observe, the anticipated REBA score has significantly decreased from 128 to 16.
While the ideal score should ideally be below Seven, the achieved reduction is remarkable.
However, there is still room for further improvement to bring the score within the ideal range.
These positive changes can be attributed to the improved body postures, indicated by the
asterisk (*) symbols in the table. Let's discuss what those changes mean.

Previously, the trunk position received a score of Two, indicating that employees had their
trunks bent forward or sideways. However, with the implementation of the spring support
mechanism, the trunk position now receives a score of One, indicating an upright or slightly
bent posture. This improvement is attributable to the optimal height achieved by the load,
which prevents excessive bending and promotes better ergonomics.

Similarly, the arm position previously scored a Two, indicating a slightly raised or lowered
posture required for loading and unloading materials onto and off the trolley. With the new
design, the arm position now receives a score of One, signifying a relaxed state, as the trolley
is set at an optimal height. This adjustment reduces strain and enhances comfort during
material handling tasks.

In terms of force analysis, the previous score was Two, indicating the use of light force due to
the maximum weight of the raw materials being 25 kilograms. However, there was an
increase in force required due to the height difference when picking up materials from the
bottom of the trolley. With the introduction of the new trolley design, this issue has been
mitigated, resulting in a score of One for force analysis. This signifies that very light force is
now required.

Overall, these modifications have significantly enhanced the ergonomics of the trolley
design. The trunk position is more upright, the arm position is more relaxed, and the force
required for material handling has been minimized. These improvements contribute to a safer
and more comfortable working environment for employees.

Now the detailed Part drawings,sub assemblies and complete or full assembly of the
Ergonomic Trolley are presented starting from Figure 3.7 up to Figure 3.22 as follows.

31
Figure 3.7 WHEEL ASSEMBLY

32
Figure 3.8 WHEEL

33
Figure 3.9 SHAFT

34
Figure 3.10 BUSH

35
Figure 3.11 CLIP

36
Figure 3.12 BRACKET

37
Figure3.13 BOARD

38
Figure 3.14 HANDLE

39
Figure 3.15 FIXED LOWER BOLT

40
Figure 3.16 FIXED UPPER BOLT

41
Figure 3.17 SCISSOR SUPPORT BOLT

42
Figure 3.18 WHEEL ATTACHING BOLT

43
Figure 3.19 COMMON NUT

44
Figure 3.20 SCISSOR SUPPORT

45
Figure3.21 SUPPORT WHEEL

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Figure 3.22 ASSEMBLY OF ERGONOMIC TROLLEY

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3.7 Conclusion and recommendation
Overall, the implementation of Ergonomics in the workplace has proven to be effective in
creating a safer and more efficient work environment for employees. This not only reduces
the risk of work-related injuries but also boosts employee motivation and work discipline.
The design of the Ergonomic Spring Trolley serves as a prime example of how ergonomic
tools can significantly minimise the occurrence of injuries which improves productivity of
employees.

Altough it has been tried to address the High priority Hazzard, there are multiple remaining
hazards that are still putting workers in danger. Accordingly here is my recommendation for
the implementation of the new design ergonomic trolley and addressing the remaining
ergonomic hazards that were identified during this project:

 Continuously assess and improve upon existing ergonomic tools and practices,
including the implementation of the new design ergonomic trolley, to further enhance
workplace safety and efficiency. Provide training and education to employees on the
importance of ergonomics and how to utilize ergonomic tools effectively.
 Implement regular maintenance and inspection of the HDPE extrusion machine to
prevent coolant leaks. Use safety barriers or warning signs to restrict access to areas
with coolant leaks and ensure workers are aware of the hazards. Consider redesigning
the layout of the workplace to minimize the need for workers to bend or crouch in wet
areas, reducing the risk of musculoskeletal disorders.
 Address the lack of adequate ventilation by using personal protective equipment,
implementing a regular maintenance and cleaning schedule for all machinery, and
improving the ventilation system by installing more openings to the factory.
 Resolve the issue of lack of storage for finished products by preparing a separate
storage unit, devising a system for storing products that maximizes space utilization,
and developing a system for quickly removing finished products and scrap materials
from aisle ways and exits in the event of an emergency.
 Address the lack of multiple emergency exits by installing additional emergency exits
in the building, widening existing exits, improving visibility and clarity of signage
and lighting, conducting regular drills, and providing training on emergency
evacuation procedures.
 Focus on implementing ergonomic solutions for improper lifting and carrying to
reduce the risk of Musculoskeletal Disorders (MSDs). Utilize ergonomic equipment
such as lifting aids, carts, and dollies, including the new design ergonomic trolley that
adjusts to the weight of the load. This will reduce physical strain on workers, improve
safety, and promote efficiency and productivity in the workplace.

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4. CHAPTER FOUR
4.1 General conclusion and Recommendation
In conclusion, my internship experience at EXCEL PLASTICS has taught me the importance
of addressing ergonomic safety, maintaining effective communication and coordination, and
investing in modern equipment and technology. While EXCEL PLASTICS is known for
producing high-quality and durable plastic products, there is always room for improvement in
areas such as space utilization and maintenance scheduling.

To address these issues, I recommend that EXCEL PLASTICS prioritize the reorganization
of the old factory layout to optimize space usage and reduce the risk of injury. Additionally,
the company should implement ergonomic safety measures and provide regular training for
employees to ensure their comfort and safety while working. Improving communication and
coordination among workers and middle-level managers can also help to ensure a smooth
flow of operations. Furthermore, prioritizing maintenance scheduling and investing in
modern equipment and technology can improve production efficiency and product quality,
leading to increased profits. By continually assessing and improving these areas, EXCEL
PLASTICS can remain competitive in the market and provide a safer and more productive
work environment for its employees.

Overall, my internship experience at Excel Plastics has been a valuable learning opportunity,
and I recommend that the company continues to focus on improving its operations and
prioritizing the safety and well-being of its employees. Additionally, addressing issues such
as space utilization and maintenance scheduling can lead to increased efficiency and
profitability for the company. By implementing these recommendations, Excel Plastics can
continue to produce high-quality products while providing a safe and productive work
environment for its employees.

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 References
1. International Ergonomics Association. (2018). What is Ergonomics? Retrieved from
https://iea.cc/what-is-ergonomics/

2. Ergo Scan. (n.d.). Ergo Scan Project. Retrieved from https://www.ergoscan.nl/en/

3. Occupational Safety and Health Administration. (n.d.). Ergonomics. Retrieved from

https://www.osha.gov/ergonomics

4. National Institute for Occupational Safety and Health. (2019). Ergonomics and
Musculoskeletal Disorders. Retrieved from
https://www.cdc.gov/niosh/topics/ergonomics/default.html

5. Wiegmann, D. A., & Shappell, S. A. (2003). A human error approach to aviation accident
analysis: The human factors analysis and classification system. Ashgate Publishing, Ltd.

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