DESIGN AND ERGONOMICS ANALYSIS OF UTeM BUS...

DESIGN AND ERGONOMICS ANALYSIS OF

UTeM BUS COCKPIT ARRANGEMENT

MOHD NASHROL BIN MOHD NAWI

UNIVERSITI TEKNIKAL MALAYSIA MELAKA

DESIGN AND ERGONOMICS ANALYSIS OF

UTeM BUS COCKPIT ARRANGEMENT

MOHD NASHROL BIN MOHD NAWI

This report is submitted in

fulfilment of the requirements for the award of

Bachelor of Mechanical Engineering (Design & Innovation)

Faculty of Mechanical Engineering

Universiti Teknikal Malaysia Melaka

JULY 2012

SUPERVISOR DECLARATION

“I hereby declare that I have read this project and in my opinion this project is

sufficient in terms of scope and quality for the award of the degree of

Bachelor of Mechanical Engineering (Design & Innovation)”

Signature:

Name: Mr Shafizal bin Mat

Date: 2 July 2012

Dedication

For father and mother loved ones

ii

DECLARATION

“I hereby declare that the work in this project is my own except for summaries and

quotations which have been duly acknowledged.”

Signature:

Name: Mohd Nashrol bin Mohd Nawi

Date: 2 July 2012

iii

ACKNOWLEDGEMENT

Greatest thanks to ALLAH S.W.T for blessing and giving me the ability to

finish this project, which hopefully can contribute in further research

I would like to express my gratitude to my supervisor, Mr. Shafizal bin Mat,

who guided me through the process of completing this report. He help, give advice

and guidance to me how to make analysis of this project and how to prepare the

report in the correct way.

A lot of thanks to all of my friends who assisting and supporting me on

completing the report. They share and provide me with brilliant ideas on how to

design the product and supporting me in boosting up my confidence level to finish

this project.

Finally, I would like to express my thanks and love to my family that

encourages and supports me in full for every trial that I have encountered. They not

only helped me financially, but morally and spiritually.

Thanks.

iv

ABSTRACT

This project is about design and ergonomics analysis of UTeM bus cockpit

arrangement. Ergonomics analysis will be applied within this project to investigate

why UTeM bus driver having some problems when they are driving. There are some

problems happen to driver bus like lower back pain, bus cockpit space area limited

and etc. This study is focusing on UTeM bus cockpit arrangement and the target user

is UTeM bus driver. There are some compartments included in the bus cockpit such

as steering, pedal, seat, gear lever, parking brake and instrument panel. Engineering

design concept was used in this project to get the information and data that related

like Pugh method and House of Quality (HOQ). Five concept of conceptual design

must come out before selection design done. Each concept has been designed with

various designs where the position of the gear lever and parking brake is modified

while the driver's seat adjusted in various ways. The best design has been selected

using the Pugh method. Concept 1 was chosen as the best concept design of cockpit

arrangement. The existing and new design of bus cockpit had been drawn using

CATIA and ergonomics analysis is applied to get ergonomics result from the design.

Comparison is made on the design of new and existing to see if the new design more

ergonomic or not. The final result for existing design is 5 over 8 and the comparison

shows that the new design is more ergonomics compare with the existing design with

overall final score of 3 over 8. The new design can be used in the future to build a

real cockpit bus arrangement and it will minimize and prevent any injury to bus

driver when driving.

v

ABSTRAK

Projek ini adalah mengenai reka bentuk dan analisis ergonomik terhadap

susunan kokpit bas UTeM. Analisis ergonomik akan digunakan dalam projek ini

untuk mengenalpasti masalah yang dihadapi oleh pemandu bas UTeM apabila

mereka memandu. Terdapat beberapa masalah berlaku kepada pemandu bas seperti

sakit bahagian belakang badan, kawasan ruang kokpit bas terhad dan sebagainya.

Kajian ini memberi tumpuan kepada susunan kokpit bas UTeM dan pemandu bas

UTeM sebagai sasaran pengguna. Terdapat beberapa bahagian di dalam kokpit bas

seperti stereng, pedal, tempat duduk, tuil gear, brek tangan dan panel instrumen.

Konsep rekaan kejuruteraan telah digunakan dalam projek ini untuk mendapatkan

maklumat dan data yang berkaitan seperti kaedah Pugh dan Rumah Kualiti (HOQ).

Lima konsep reka bentuk mesti direka sebelum pemilihan reka bentuk dilakukan.

Setiap konsep telah direkabentuk dengan pelbagai rekaan di mana kedudukan tuil

gear dan brek tangan diubahsuai manakala tempat duduk pemandu dipelbagaikan

dalam pelbagai cara. Reka bentuk yang terbaik akan dipilih menggunakan kaedah

Pugh. Konsep 1 telah dipilih sebagai konsep reka bentuk susunan kokpit yang

terbaik. Reka bentuk kokpit bas yang sedia ada dan baru akan dilukis menggunakan

CATIA dan analisis ergonomik (RULA analisis) digunakan untuk mendapatkan

keputusan ergonomik. Perbandingan dilakukan terhadap reka bentuk baru dan sedia

ada untuk melihat sama ada reka bentuk baru lebih banyak ergonomik atau tidak.

Keputusan rekabentuk asal adalah 5 daripada 8 dan perbandingan menunjukkan reka

bentuk baru adalah lebih ergonomik dibandingkan dengan reka bentuk yang sedia

ada dengan skor keseluruhan akhir sebanyak 3 daripada 8. . Reka bentuk baru ini

boleh digunakan pada masa hadapan untuk membina susunan kokpit bas yang

sebenar. Reka bentuk baru ini boleh meminimumkan dan menghalang apa-apa

kecederaan kepada pemandu bas ketika memandu.

vi

TABLE OF CONTENT

CHAPTER TITLE PAGES

DECLARATION ii

ACKNOWLEGDEMENT iii

ABSTRACT iv

ABSTRAK v

TABLE OF CONTENT vi

LIST OF FIGURES x

LIST OF FIGURES xiii

CHAPTER 1 INTRODUCTION

1.1 Project Background 1

1.2 Problem Statement 2

1.3 Objectives 2

1.4 Scope 2

1.5 Methodology 3

1.6 Project Outline 4

1.7 Summary 9

CHAPTER 2 LITERATURE REVIEW

2.1 Introduction 10

2.2 Ergonomics 11

2.2.1 Human Factors And Ergonomics 13

2.3 Driver Distraction 14

2.4 Lower Back Pain (LBP) 15

2.5 Fundamental of Seating and Positioning 18

vii

2.6 Anthropometry 20

2.7 Posture 23

2.7.1 Postural Loading 24

2.7.2 Vision and Posture of Head and Neck 25

CHAPTER 3 METHODOLOGY

3.1 Introduction 28

3.2 Design Process 28

3.3 Analysis Method 30

CHAPTER 4 CONCEPTUAL DESIGN AND SELECTION DESIGN

4.1 Introduction 31

4.2 Existing Design 32

4.3 House of Quality (HOQ) 33

4.4 Best Concept Generated 37

4.5 Ergonomics Analysis 40

4.5.1 Concept 1 40

4.5.1.1 Driver bus sitting and hold

steering position 40

4.5.1.1 Driver bus hold gear lever 41

4.5.1.2 Driver bus pull parking brake 42

4.5.2 Concept 2 44


steering postition 44



4.5.3 Concept 3 48





4.5.4 Concept 4 52

viii





4.5.5 Concept 5 56





4.6 Concept Evaluation 60

4.7 Selection Design 61

CHAPTER 5 RESULTS AND DISCUSSION

5.1 Introduction 64

5.2 Existing design ergonomics analysis 65

5.2.1 Sitting and hold Steering 65

5.2.2 Hold gear lever 66

5.2.3 Pull parking brake 67

5.3 New design ergonomics analysis 68

5.3.1 Sitting and hold steering 68

5.3.2 Hold Gear 69


5.4 Comparison between existing and new design 71

5.4.1 Sitting and hold steering 72

5.4.2 Hold gear lever 73


5.5 Discussion 77

CHAPTER 6 CONCLUSION AND RECOMMENDATION

6.1 Conclusion 78

6.2 Recommendation 79

ix

REFFERENCES 80

APPENDICES 83

x

LIST OF FIGURE

NO TITLE PAGES

Figure 1.1 Outline of project 5

Figure 1.2 Project Flow Chart 6

Figure 2.1 Seat mounted on a seat buck and postural angles and

design specification.(Source: Se Jin Park et al., 2000) 18

Figure 2.2 Posture when driving (Source :http://marklandclinic.com/

blog/2010/12/driving-posture-and-ergonomics) 19

Figure 2.3 Three different sitting postures

(Source: Nobuyuki Shibata & Setsuo Maeda, 2010) 20

Figure 2.4 The interior Space Envelopes

(Source: Waldemar Karwowski, 2006) 20

Figure 2.5 Raw data and Overlaid RAMSIS analysis

(Source: Thomas Seitz, 2000) 21

Figure 2.6 Posture theory diagram (Source: www.antiaginghacks.com

/six-tips-for-fighting-bad-posture) 23

Figure 2.7 Postural stress at the lumbo- sacral joint in the spine.

(Source: Stephen Pheasent et al., 2006) 24

Figure 2.8 Vision zones and posture of head and neck

(Source: Stephen Pheasent, 2006) 26

Figure 4.1 Existing UTeM bus cockpit 32

Figure 4.2 Existing design (CAD view) 33

Figure 4.3 Concept 1 37




xi


Figure 4.8 Sitting and Hold Steering (Left) 40

Figure 4.9 Sitting and Hold Steering (right) 41

Figure 4.10 Hold gear lever (left) 41

Figure 4.11 Hold gear lever (right) 42

Figure 4.12 Pull parking brake (right) 43

Figure 4.13 Pull parking brake (left) 43

Figure 4.14 Sitting and hold steering (right) 44

Figure 4.15 Sitting and hold steering (left) 45























Figure 4.38 New cockpit arrangement design (CAD drawing) 63

Figure 4.39 New cockpit arrangement design (drafting) 63

xii

Figure 5.1 Existing design when sitting and hold steering (right) 65

Figure 5.2 Existing design when sitting and hold steering (left) 65

Figure 5.3 Existing design when hold gear lever (right) 66

Figure 5.4 Existing design when hold gear lever (left) 66

Figure 5.5 Existing design when pull parking brake (right) 67

Figure 5.6 Existing design when pull parking brake (left) 68

Figure 5.7 New design when sitting and hold steering (left) 68

Figure 5.8 New design when sitting and hold steering (right) 69

Figure 5.9 New design when hold gear lever (left) 69

Figure 5.10 New design when hold gear lever (right) 70

Figure 5.11 New design when pull parking brake (right) 71

Figure 5.12 New design when pull parking brake (left) 72

xiii

LIST OF TABLE

NO TITLE PAGES

Table 1.1 PSM 1 Gantt Chart 7

Table 2.2 PSM 2 Gantt Chart 8

Table 2.1 The fractions (%) of service route driving

with different models of bus

(Source: Olanrewaju O. Okunribido et al., 2007) 16

Table 2.2 Values for 5th to 95th percent

(Source: Scott Openshaw et al., 2006) 22

Table 2.3 Joint comforts ranges for a seated driver (degrees)

(Source: Rabiffe, 1966) 25

Table 2.4 Percent of rear-struck drivers with pain by location of pain

(Source: Janella F. Chapline et al., 2000) 27

Table 4.1 House of Quality (HOQ) 35

Table 4.2 Ergonomics result when driver sitting and hold steering 60

Table 4.3 Ergonomics result when driver hold gear lever 60

Table 4.4 Ergonomics result when driver pull parking brake 61

Table 4.5 Pugh method for comparing the concept design 62

Table 5.1 Sitting and hold steering (Right) 72

Table 5.2 Sitting and hold steering (Left) 73

Table 5.3 Hold gear lever (Right) 74

Table 5.4 Hold gear lever (Left) 74

Table 5.5 Pull parking brake (Right) 75

Table 5.6 Pull parking brake (Left) 76

1

CHAPTER 1

INTRODUCTION

1.0 Project Background

Ergonomics is a combination of the words ergo, a Greek word meaning

"work" and nomics, meaning "study" - the study of work. An applied science that co-

ordinates the design of devices, systems and physical working conditions with the

capacities and requirements of the workers (N. Jaffar et al., 2011).

Nowadays, public transport is one priority to consumer to travel anywhere.

Public transport forms the major use of buses, taxi, and train. This public transport

designed for the transport of the general public as a public service. A significant

problem in the public transport sector is driver distraction (Salmon et al., 2011).

There are various methods exist for investigating distraction. However, the majority

are difficult to apply within the context of naturalistic bus driving. Thus, this project

is proposed to design bus cockpit using ergonomic analysis. In this project,

ergonomics was applied to investigate why driver distraction when they driver. This

project will be focusing on UTeM bus cockpit.

Cockpit is well known as a compartment in a small aircraft in which the pilot,

crews and sometimes passanger sit. However, for bus, cockpit defined as the bus

driver compartment to driving that required steering, gear lever, seat, parking brake,

pedal and instrument panel that include all button of bus functions like button for

2

door open and close. These are the basics component that have at cockpit. Each

compartments at the bus cockpit have their own functions.

1.1 Problem Statement

The driver should be patience and focus in their driving in order to avoid

accident occurs. The driver will face some problems during they drive and it will

affect them when they are driving. Same goes to UTeM bus driver, distraction while

driving is a major problem to the bus driver.

Besides, they do not feel comfortable with the current bus driver cockpit

arrangement. The bus cockpit arrangement not suitable for driver to drive in whole

day to pick up student from hostel to campus. It a bit difficult for driver to touch each

buttons at the bus instrument panel and it will interfere driver driving.

Driver bus also get some problem when moving around the cockpit especially

for fat or big driver bus because the space aroud is too limited. These problems can

cause the driver not feel comfortable when sitting and can make them lost their focus

to driving. Besides that, driver bus easy to get back pain when they driving especially

at the lower back and easy to feel tired.

1.2 Objectives

The main objectives of this project is to design and perform the ergonomics

analysis for UTeM bus cockpit arrangement.

1.3 Scope

The scopes that want to achieved for this project to make successfull and

fullfill the objectives are re-design the UTeM bus cockpit arrangement that already

3

made for UTeM’s driver bus used. Besides that, the design of cockpit arrangement

must perform the new ergonomics design analysis to make a suitable, variable

condition and comfortable design for UTeM’ driver bus.

The new ergonomics design of UTeM bus cockpit must do a comparison

between the existing UTeM bus cockpit design to get the result that can make UTeM

bus driver comfortable and can focus without no distraction when driving and not

feel so tired to drive on long journey. This ergonomics design must be evaluated by

using the CATIA ergonomics analysis to get the result of the new ergonomics

design.

1.4 Methodology

Many methods have been used to gain an information about the UTeM bus

cockpit arrangement. The method used are doing an interview with UTeM driver

bus, and doing article review about the ergonomics function of the bus cockpit

arrangement.

The interview done by do talk with UTeM driver bus to know what effect

while they driving. The interview gain some information that can be used and doing

some research about the problems they face. Besides that, internal sources like

journal, article and books have been used to gain information about the bus cockpit

arrangement such as ergonomics posture while driving.

For the ergonomic analysis, CATIA software have been used. The software

will give result about the ergonomics analysis from the existing UTeM bus cockpit

and new concept design of UTeM bus cockpit. The result for existing and new

concept design will be used to compare to get the best ergonomics result.

4

1.5 Project Outline

This research will be divided into six chapters. The first chapter is mainly

about the introduction of the project, problem statement, objectives and lastly the

project outline.

Chapter two is the literature review. Based on the references gathered

(journals, books, websites, article etc.), this chapter will discuss the definition and

introduction of ergonomics, bus driver distraction and bus cockpit arrangement. It

will also discuss the method on how the research will be done based on the past

researches.

Chapter three will be discussing about the review of the research

methodology. This will include the design and framework of the study. This chapter

will also discussing about the advantage and disadvantage of the methods chosen

where ergonomomic analysis method and the drawing of the actual design of cockpit

arrangement.

Chapter four is about the conceptual design. The new concept design will be

drawn by using CATIA software and it will be analyzed to perfom the ergonomics

analysis of the new concept of cockpit arrangement.

Chapter five is discussion of the project analysis. The result get from both

actual and new concept design will be compared and discussed. This will include the

setup for the data collection, the data collection table and the example of the data

which had been taken in this chapter. The data result and the findings during the

project research will be compared and discussed in details

In the last chapter, the conclusion and the recommendation will be reviewed.

This chapter will concluded the project and give some suggestion will be given for

future research. Figure 1.1 shows the outline of this project.

5

Figure 1.1 Outline of project

Figure 1.2 shows the flow chart of this project. Each chapter of this project

will based on the project flow chart. The chapters include in this project are literature

review, existing design analysis, conceptual design, detail design, result and

discussion and lastly the conclusion and recommendation of this project.

6

Figure 1.2 Project Flow Chart

Yes

No

Discussion and Recommendation

Report writing

Accept

Selection Design

Detail design ( CAD drawing )

Result

Data processing

Ergonomics Analysis

Ergonomics Analysis

Conceptual design

Literature Review

New design Existing design

CAD drawing

Data processing

Result

Checking and Improvement

7

Table 1.1 shows the Gantt chart for PSM 1. The tasks needed to complete

this project are listed sequently in the vertical axis and the estimated time to

accomplish the task are shown along the horizontal axis of this Gantt chart.

Table 1.1 PSM 1 Gantt Chart

PSM 1 Gantt Chart

Activity Week 1 2 3 4 5 6 7 8 9 10 11 12 13 14

Project Proposal • Title Selection • Supervisor Verification Chapter 1 : Introduction • Objective, Scope,

Problem Statement & Methodology

• Correction Chapter 2 : Literature Review • Journal, Article & Books

review

• Correction Seminar 1 (Poster) • Preparation • Submit Chapter 3 : Methodology • Flow Chart of Project

process

• Process of Analysis • Correction Seminar 2 (Presentation) • Preparation • Presentation PSM 1 Report Drafting • Preparation • Report PSM 1 Submit

8

Table 1.2 shows the Gantt chart for PSM 2. The tasks needed to complete

this project are listed sequently in the vertical axis and the estimated time to

accomplish the task are shown along the horizontal axis of this Gantt chart. To

finished this project, the Gantt chart must followed.

Table 1.2 PSM 2 Gantt Chart

Activities PSM 2 (2012)

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Chapter 4 :Conceptual Design & Selection Design Sketching Concept Evaluation Concept Selection

Detail Design Seminar 1 (Poster) -

PSM 2 Preparation Submit Chapter 5 : Results & Analysis Ergonomics Analysis Result Comparison Chapter 6 : Conclusion and Recommendation Conclusion & Recommendation Seminar 2 (Presentation) - PSM 2 Preparation PSM 1 & 2 Report Drafting Preparation Compile PSM 1 & PSM 2 Report PSM Submit

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