In ice manufacturing process, there have a few of activity will involve the manual handling movement by worker. For example, hammering, pushing and pulling the ice blocks. All of this manual handling movement will contribute the ergonomic risk to worker. This research is aimed to identify, evaluate and analyze ergonomic issues at Kilang Air Batu PNK Kuala Perlis in an ice block production process. In the ice block
production process, the focus is on ice block flattening process. This is because flattening process involves repetitive task with high frequency of hammering action. The method that had been use for assess the current condition of worker in the factory is Nordic Musculoskeletal Questionnaire, observation and initial Ergonomic Risk Assessment. After that, the advance Ergonomic Risk Assessment was conducted by using Occupational Repetitive Action (OCRA) to assess repetitive task in flattening process. Both OCRA Index and OCRA Checklist were used to evaluate the upper limb condition of worker. Since the worker perform the process in different location from time to time, the assessment selected on three different locations (front, middle, back). The assessment results showed that OCRA index score for three different location front, middle and back is 4.67, 4.36 and 3.92. The score value for OCRA checklist is 15.29, 14.65 and 13.71. Both result showed that the current condition for worker is in medium risk level for both OCRA Index and Checklist. The ergonomic intervention was implemented by redesigning the tool used in flatten process. After intervention, the reassessment by using OCRA Index and OCRA Checklist were conducted and it was clearly shown that the OCRA Index reduce to 3.4, 3.2 and 2.86 for front, middle and back location. Similarly, OCRA Checklist value reduced to 12.41, 12.09 and 11.58. As a conclusion, the intervention have successfully improved the worker condition in flatten process for the Kilang Air Batu PNK Kuala Perlis.
