Effects of two ergonomic improvements in brazing coils of air-handler units

• We address physically loading, quality and productivity problems in coil brazing.
• Intervention I uses twin brazing torch (TBT) to replace the single brazing gun.
• Intervention II uses TBT in sitting position.
• Results: 58.9% quality and 140% productivity improvements and 113 times ROI.
• Include reductions in bending of left and right wrists, neck and back.

The research aims to address the physically loading task and quality and productivity problems in the brazing of coils of air-handler units. Eight operators participated in two intervention studies conducted in a factory in Malaysia to compare the status quo brazing with (1) the use of a new twin-brazing torch that replaced the single-brazing gun and (2) brazing in a sitting position. The outcome measures are related to quality, productivity, monetary costs, body postures and symptoms. After baseline, Interventions I and II were applied for 3 months respectively. The results show a 58.9% quality improvement, 140% productivity increase and 113 times ROI. There was also a reduction in poor work postures e.g. in the raising of the arms and shoulders; bending, twisting and extending of the neck; and bending of left and right wrists, and the back. This research can be replicated in other factories that share similar processes.