Copeland Ergonomics Project

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Copeland Ergonomics Project

• University of Dayton
• Tom Neuberger
• Melani Smajdek
• Dan Smola

2
Outline

• Project Overview
• Requirements
• Criteria
• Designs
• Decision Analysis
• Conclusion
• Gantt Chart

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Project Overview

• Investigate ergonomic issues on Copelands scroll
  compressor production line
• Observation of workers
• Task analysis
• Reported injury data
• Improve working conditions with regards to
  ergonomic issues

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Schematic of work area

• Two different compressors
• Quantum-smaller
• Summit-larger

Station 1
Station 2
Station 3
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Project Scope

• Design tasks divided into three stations
• Remove compressor from chain
• Tube inspection
• Plug replacement

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Design Requirements

• Station 1
• Adjustable to different size compressors
• Release compressor from hook
• Place compressor on existing pallets
• Rotate compressors 90 degrees
• Handle reject compressors
• Keep pace with overhead chain
• Handle back-ups further down the line

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Design Requirements contd

• Station 2 and 3
• Accommodate various plug sizes and tube locations
• Necessary tools should be easily accessible

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Design Criteria

• Reduce reaching, pushing, pulling and other
  stresses felt by workers
• Reduce injuries associated with repetitive and
  stressful actions
• Minimize injury to workers due to mishandled
  compressors
• Keep workers safe from pinch points

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Design Criteria contd

• Accommodate workers with different physical
  characteristics
• Integrate into existing system
• Protect compressors from damage

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Injury Data

• Common injuries
• Carpal Tunnel Syndrome
• Tendonitis
• Strains
• Sprains
• Lacerations
• Bruises

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Tasks and Concept Designs

• Station 1 Remove compressor from chain
• Station 2 Tube inspection
• Station 3 Plug replacement

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Station 1 Remove Compressor From Chain

• Remove compressor from overhead chain using lift
  system
• Remove plugs from two locations on compressor
• Rotate 90 degrees to ready for next station
• Push compressor down the line

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Station 1 Remove Compressor From Chain

• Jerking stresses are created by lift
• Bending and other stresses on back
• Heavy lifting is required
• Overextension is encountered by operators
• Repetitive motions exist during operation
• Operators safety is at risk

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Station 1 Remove Compressor From Chain

• Rotating and lifting pallets for reject/overflow
  storage
• Automated track for overflow compressors
• Spring loaded pallet storage

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Station 1 Remove Compressor From Chain
Storage lanes approx 16 pallets per lane
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Station 1 Remove Compressor From Chain
Guards
Roller Curve Conveyor
Horizontal Belt Conveyor
Horizontal Belt Conveyor
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Station 1 Remove Compressor From Chain
Horizontal Belt Conveyor
Roller Curve Conveyor
Ball Transfer Table
Current Conveyor
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Station 1 Pallet Storage
Contains approx 40 pallets
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Decision Analysis
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Tasks and Concept Designs

• Station 1 Remove compressor from chain
• Station 2 Tube inspection
• Station 3 Plug replacement

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Station 2 Tube Inspection

• Copper tubing inner diameter check using go-no go
  cylindrical gage
• Use of ergonomic hammer and tool to repair copper
  tubing if deformed

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Station 2 Tube Inspection

• Continuous hand and wrist fatigue from repetitive
  twisting motion
• New U-shaped tooling will eliminate the twisting
  of the wrist

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Station 2 Tube Inspection

• Number of tools used causes excessive reaching
• Aprons with pockets to hold tools eliminates
  reaching for tools
• Twisting action to retrieve plastic covers and
  screws
• Reorganize storage table

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Station 2 Tube Inspection

• Application of cover over electric plug with open
  palm
• Requires force from palm to fit cover in place
• Impact Mitt - glove with solid palm hand
  protection and padding to reduce impact and
  vibration

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Tasks and Concept Designs

• Station 1 Remove compressor from chain
• Station 2 Tube inspection
• Station 3 Plug replacement

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Station 3 Plug Replacement

• Plug replacement using T-bar
  tool and Vaseline lubricant
• Different heights of copper tubing require
  reaching and bending when applying force
• Lift with safety guards raises large compressor
  to working level

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Station 3 Plug Replacement
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Station 3 Plug Replacement

• Different plug sizes require different tools
• Excessive reaching and leaning causes stresses on
  back
• New tooling to accommodate all plug sizes
• Larger impact area decreases stress in hand

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Station 3 Plug Replacement

• Opposite hand supports compressor when replacing
  the plugs
• Excessive reaching and stress on back
• Employ back stop to support the force of the
  worker replacing the plugs
• Back stop used for both sizes of compressor

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Gantt Chart
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Future Tasks

• Develop details of designs
• Detailed drawings
• List of purchase parts
• Analysis and justification of cost