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  1. Dawal SZ, Taha Z
    J Hum Ergol (Tokyo), 2004 Dec;33(1-2):19-27.
    PMID: 17402505 DOI: 10.11183/jhe1972.33.19
    A survey was conducted to investigate the relationship between job satisfaction and job factors that affect work design in two automotives manufacturing companies in Malaysia. A set of multiple choices questionnaires was developed and data were collected by interviewing the employees at the production plant. Hundred and seventy male subjects between the ages of 18 to 40 years with the mean age of 26.8 and SD of 5.3 years and mean work experience of 6.5 and SD of 4.9 years took part in the survey. The survey focused on job factors, i.e. skill variety, task identity, task significance, autonomy and feedback. The results support the previous findings that job factors are significantly correlated to job satisfaction. Furthermore, it also highlights the significant influence of age, work experience and marital status.
  2. Dawal SZ, Taha Z
    Int J Occup Saf Ergon, 2006;12(3):267-80.
    PMID: 16984786
    A methodology was developed for diagnosing industrial work, which includes questionnaire, observation, measurements, data collection and statistical analysis. A survey was conducted to investigate the relationship between job satisfaction and factors that affect work design in 2 automotives manufacturing companies in Malaysia. A basic work design model was proposed. The aim of this model was to determine the factors that influence employees' perception towards their work. A set of multiple-choice questionnaires was developed and data was collected by interviewing employees at a production plant. The survey focused on job and environmental factors. The results supported the proposed model and showed that job and environmental factors were significantly related to job satisfaction. They highlighted the significant influence of age, work experience and marital status on job satisfaction. Further, environmental factors, especially the surroundings, context dependence and the building's function, also had a significant impact on job satisfaction.
  3. Dawal SZ, Taha Z
    J Hum Ergol (Tokyo), 2007 Dec;36(2):63-8.
    PMID: 18572797 DOI: 10.11183/jhe1972.36.2_63
    A methodology is developed in diagnosing the effect of job organizational factors on job satisfaction in two automotive industries in Malaysia. One hundred and seventy male subjects of age 18-40 years with the mean age of 26.8 and standard deviation (SD) of 5.3 years and the mean work experience of 6.5 years and SD of 4.9 years took part in the study. Five job organizational factors were tested in the study including job rotation, work method, training, problem solving and goal setting. A job organization questionnaire was designed and was based on respondents' perception in relation to job satisfaction. The results showed that job organization factors were significantly related to job satisfaction. Job rotation, work method, training and goal setting showed strong correlation with job satisfaction while problem solving had intermediate correlation in the first automotive industry. On the other hand, most job organization factors showed intermediate correlation with job satisfaction in the second automotive industry except the training factor which had low correlation with job satisfaction. These results highlight that job rotation, work methods, problem solving and goal setting are outstanding factors in the study of job satisfaction for automotive industries.
  4. Tahriri F, Dawal SZ, Taha Z
    ScientificWorldJournal, 2014;2014:505207.
    PMID: 24982962 DOI: 10.1155/2014/505207
    A new multiobjective dynamic fuzzy genetic algorithm is applied to solve a fuzzy mixed-model assembly line sequencing problem in which the primary goals are to minimize the total make-span and minimize the setup number simultaneously. Trapezoidal fuzzy numbers are implemented for variables such as operation and travelling time in order to generate results with higher accuracy and representative of real-case data. An improved genetic algorithm called fuzzy adaptive genetic algorithm (FAGA) is proposed in order to solve this optimization model. In establishing the FAGA, five dynamic fuzzy parameter controllers are devised in which fuzzy expert experience controller (FEEC) is integrated with automatic learning dynamic fuzzy controller (ALDFC) technique. The enhanced algorithm dynamically adjusts the population size, number of generations, tournament candidate, crossover rate, and mutation rate compared with using fixed control parameters. The main idea is to improve the performance and effectiveness of existing GAs by dynamic adjustment and control of the five parameters. Verification and validation of the dynamic fuzzy GA are carried out by developing test-beds and testing using a multiobjective fuzzy mixed production assembly line sequencing optimization problem. The simulation results highlight that the performance and efficacy of the proposed novel optimization algorithm are more efficient than the performance of the standard genetic algorithm in mixed assembly line sequencing model.
  5. Hashim AM, Dawal SZ, Yusoff N
    Work, 2012;41 Suppl 1:827-31.
    PMID: 22316824 DOI: 10.3233/WOR-2012-0249-827
    The objective of this study is to compare the evaluation of postural analysis between a self-report questionnaire and physical assessments methods for students aged 13 to 15 years old in school workshop. 336 students were volunteered as participants to fill in the questionnaire and being observed in the workshop. Total of 104 positions were selected and analyzed while students performing their tasks. Questionnaire data was examined to specify the prevalence of postural stress symptoms. The relationship of postural stress by physical assessment methods (RULA and REBA methods) was defined to identify the risk level of students' working posture. From the results, comparison of four factors categorized from total of 22 questions among ages, the mean values were lower for 13 years old students meaning that they were faced higher posture problems while using the workstation. The obtained results from both physical assessment methods and questionnaire analysis have identified 13 years old students faced higher risk exposure. Analysis results emphasized the fact that self-reports questionnaire method has almost accurate as postural evaluation methods to identify physical risks in workplace. The result also shows that an intervention is needed to overcome the posture problems.
  6. Zadry HR, Dawal SZ, Taha Z
    Int J Occup Saf Ergon, 2011;17(4):373-84.
    PMID: 22152503
    A study was conducted to investigate the effects of repetitive light tasks of low and high precision on upper limb muscles and brain activities. Surface electromyography (EMG) and electroencephalography (EEG) were used to measure the muscle and brain activity of 10 subjects. The results show that the root-mean-square (RMS) and mean power frquency (MPF) of the muscle activity and the mean power of the EEG alpha bands were higher on the high-precision task than on the low-precision one. There was also a high and significant correlation between upper limb muscle and brain activity during the tasks. The longer the time and the more precise the task, the more the subjects become fatigued both physically and mentally. Thus, these results could be potentially useful in managing fatigue, especially fatique related to muscle and mental workload.
  7. Zadry HR, Dawal SZ, Taha Z
    Int J Occup Saf Ergon, 2016 Sep;22(3):374-83.
    PMID: 27053140 DOI: 10.1080/10803548.2016.1150094
    This study was conducted to develop muscle and mental activities on repetitive precision tasks. A laboratory experiment was used to address the objectives. Surface electromyography was used to measure muscle activities from eight upper limb muscles, while electroencephalography recorded mental activities from six channels. Fourteen university students participated in the study. The results show that muscle and mental activities increase for all tasks, indicating the occurrence of muscle and mental fatigue. A linear relationship between muscle activity, mental activity and time was found while subjects were performing the task. Thus, models were developed using those variables. The models were found valid after validation using other students' and workers' data. Findings from this study can contribute as a reference for future studies investigating muscle and mental activity and can be applied in industry as guidelines to manage muscle and mental fatigue, especially to manage job schedules and rotation.
  8. Kamil NS, Dawal SZ
    J Phys Ther Sci, 2015 Jun;27(6):1967-70.
    PMID: 26180359 DOI: 10.1589/jpts.27.1967
    [Purpose] This study investigated the effects of postural angle on back muscle activity during a computer task in aging women. [Subjects] Seventeen women ≥50 years old participated. [Methods] The participants were instructed to perform computer-related tasks for 20 minutes on a workstation that simulated typical office working conditions. Back posture was measured from the measured trunk and pelvic angles. Electromyography activities were recorded simultaneously from the cervical erector spinae, longissimus, and multifidus muscles. [Results] The lowest mean percentages of maximum voluntary contraction for the cervical erector spinae and longissimus muscles were obtained when the upper trunk and pelvic angles were between 0° to -5° from the sagittal plane. The back muscle activities increased as the upper trunk and pelvic angles exceeded 0°. Statistical analysis showed significant correlations between upper trunk angle and cervical erector spinae and longissimus muscle activities. Similarly, pelvic angle was significantly correlated with cervical erector spinae and multifidus muscle activities. [Conclusion] A neutral back posture minimizes muscle activities in aging women performing computer tasks.
  9. Widia M, Md Dawal SZ, Yusoff N
    PLoS One, 2019;14(5):e0216918.
    PMID: 31141545 DOI: 10.1371/journal.pone.0216918
    BACKGROUND: Extensive studies have been carried out over the years to determine the maximum acceptable weight that a worker is capable of lifting in a given situation among Occidental populations across Europe and US. Nonetheless, studies that place emphasis on using lifting frequency as the quantifying task parameter, especially in developing countries such as Malaysia, appear to be in scarcity. Hence, this study determined the maximum acceptable frequency of lift (MAFL) for combined manual material handling (MMH) tasks amongst Malaysian males.

    METHOD: Two lifting loads were considered in this study: 1 kg and 5 kg. Each subject adjusted his frequency of lifting using a psychophysical approach. The subjects were instructed to perform combined MMH task as fast as they could over a period of 45 minutes without exhausting themselves or becoming overheated. The physiological response energy expenditure was recorded during the experimental sessions. The ratings of perceived exertion (RPE) for four body parts (forearms, upper arm, lower back and entire body) were recorded after the subjects had completed the instructed task.

    RESULTS: The mean frequencies of the MMH task had been 6.8 and 5.5 cycles/minute for lifting load of 1 and 5 kg, respectively, while the mean energy expenditure values were 4.16 and 5.62 kcal/min for 1 and 5 kg load, respectively. These displayed a significant difference in the Maximum Acceptable Frequency of Lift (MAFL) between the two loads, energy expenditure and RPE (p < 0.05) whereby the subjects appeared to work harder physiologically for heavier load.

    CONCLUSION: It can be concluded that it is significant to assess physiological response and RPE in determining the maximum acceptable lifting frequency at varied levels of load weight. The findings retrieved in this study can aid in designing tasks that do not exceed the capacity of workers in order to minimise the risk of WRMSDs.

  10. Yap HJ, Taha Z, Dawal SZ, Chang SW
    PLoS One, 2014;9(10):e109692.
    PMID: 25360663 DOI: 10.1371/journal.pone.0109692
    Traditional robotic work cell design and programming are considered inefficient and outdated in current industrial and market demands. In this research, virtual reality (VR) technology is used to improve human-robot interface, whereby complicated commands or programming knowledge is not required. The proposed solution, known as VR-based Programming of a Robotic Work Cell (VR-Rocell), consists of two sub-programmes, which are VR-Robotic Work Cell Layout (VR-RoWL) and VR-based Robot Teaching System (VR-RoT). VR-RoWL is developed to assign the layout design for an industrial robotic work cell, whereby VR-RoT is developed to overcome safety issues and lack of trained personnel in robot programming. Simple and user-friendly interfaces are designed for inexperienced users to generate robot commands without damaging the robot or interrupting the production line. The user is able to attempt numerous times to attain an optimum solution. A case study is conducted in the Robotics Laboratory to assemble an electronics casing and it is found that the output models are compatible with commercial software without loss of information. Furthermore, the generated KUKA commands are workable when loaded into a commercial simulator. The operation of the actual robotic work cell shows that the errors may be due to the dynamics of the KUKA robot rather than the accuracy of the generated programme. Therefore, it is concluded that the virtual reality based solution approach can be implemented in an industrial robotic work cell.
  11. Nur NM, Dawal SZ, Dahari M, Sanusi J
    J Phys Ther Sci, 2015 Aug;27(8):2431-3.
    PMID: 26357421 DOI: 10.1589/jpts.27.2431
    [Purpose] The purpose of this study was to investigate the effects of energy expenditure rate on work productivity performance at different levels of production standard time. [Subjects and Methods] Twenty industrial workers performed repetitive tasks at three different levels of production standard time, normal, hard, and very hard. Work productivity and energy expenditure rate were recorded during the experimental tasks. [Results] The work productivity target was not attainable for the hard and very hard production standard times. This was attributed to the energy expenditure rate, which increased as the level of production standard time became harder. The percentage change in energy expenditure rate for the very hard level (32.5%) relative to the normal level was twice that of the hard level (15.5%), indicating a higher risk of work-related musculoskeletal disorders for the harder production standard time. The energy expenditure rate for the very hard production standard time (1.36 kcal/min) was found to exceed the maximum energy expenditure rate recommended for light repetitive tasks involving both arms (1.2 kcal/min). [Conclusion] The present study shows that working with an energy expenditure rate that is either equal to or above the maximum energy expenditure rate of the tasks results in decreased work productivity performance due to the onset of physical fatigue and a higher risks of work-related musculoskeletal disorders.
  12. Nur NM, Dawal SZ, Dahari M, Sanusi J
    J Phys Ther Sci, 2015 Jul;27(7):2323-6.
    PMID: 26311974 DOI: 10.1589/jpts.27.2323
    [Purpose] This study investigated the variations in muscle fatigue, time to fatigue, and maximum task duration at different levels of production standard time. [Methods] Twenty subjects performed repetitive tasks at three different levels of production standard time corresponding to "normal", "hard" and "very hard". Surface electromyography was used to measure the muscle activity. [Results] The results showed that muscle activity was significantly affected by the production standard time level. Muscle activity increased twice in percentage as the production standard time shifted from hard to very hard (6.9% vs. 12.9%). The muscle activity increased over time, indicating muscle fatigue. The muscle fatigue rate increased for the harder production standard time (Hard: 0.105; Very hard: 0.115), which indicated the associated higher risk of work-related musculoskeletal disorders. Muscle fatigue was also found to occur earlier for hard and very hard production standard times. [Conclusion] It is recommended that the maximum task duration should not exceed 5.6, 2.9, and 2.2 hours for normal, hard, and very hard production standard times, respectively, in order to maintain work performance and minimize the risk of work-related musculoskeletal disorders.
  13. Tang DKH, Md Dawal SZ, Olugu EU
    J Safety Res, 2018 Sep;66:9-19.
    PMID: 30121115 DOI: 10.1016/j.jsr.2018.05.003
    INTRODUCTION: This study establishes the correlations between performance of a set of key safety factors and the actual lagging performance of oil platforms in Malaysia, hence the relevance of the key safety factors in evaluating and predicting the safety performance of oil and gas platforms. The key factors are crucial components of a safety performance evaluation framework and each key safety factor corresponds to a list of underlying safety indicators.

    METHOD: In this study, participating industrial practitioners rated the compliance status of each indicator using a numbering system adapted from the traffic light system, based on the actual performance of 10 oil platforms in Malaysia. Safety scores of the platforms were calculated based on the ratings and compared with the actual lagging performance of the platforms. Safety scores of two platforms were compared with the facility status reports' findings of the respective platforms.

    RESULTS: The platforms studied generally had good performance. Total recordable incident rates of the platforms were found to show significant negative correlations with management and work engagement on safety, compliance score for number of incident and near misses, personal safety, and management of change. Lost time injury rates, however, correlated negatively with hazard identification and risk assessment. The safety scores generally agreed with findings of the facility status reports with substandard process containment found as a contributor of hydrocarbon leaks.

    CONCLUSIONS: This study proves the criterion validity of the safety performance evaluation framework and demonstrates its usability for benchmarking and continuous improvement of safety practices on the Malaysian offshore oil and gas platforms.

    PRACTICAL APPLICATIONS: This study reveals the applicability of the framework and the potential of extending safety reporting beyond the few conventional lagging safety performance indicators used. The study also highlights the synergy between correlating safety factors to streamline safety management on offshore platforms.

  14. Javed I, Md Dawal SZ, Nukman Y, Ahmad A
    Int J Occup Saf Ergon, 2022 Dec;28(4):2238-2249.
    PMID: 34556003 DOI: 10.1080/10803548.2021.1984673
    Work productivity is one of the most important economic measures in the manufacturing industry. However, the physical, psychosocial and individual risk factors of an industrial work environment affect workers' physical or mental health, resulting in work productivity loss, absenteeism and presenteeism. Therefore, this study aims to identify the most critical risk factors and develop statistical models for predicting work productivity loss, absenteeism and presenteeism of garment industry workers. A sample of 224 sewing machine operators was taken for data collection through observation and self-reported studies. The results indicated that the average work productivity loss, absenteeism and presenteeism was 38.21, 2.35 and 37.23%, respectively. Finally, the statistical models of work productivity loss, absenteeism and presenteeism was developed using multiple linear regression with precision of 69.9, 53.7 and 84.0%, respectively. Hence, this study will help garment industries to improve their work productivity by taking initiatives based on the developed models.
  15. Bhuiyan MSH, Choudhury IA, Dahari M, Nukman Y, Dawal SZ
    Appl Bionics Biomech, 2017;2017:7595642.
    PMID: 28584518 DOI: 10.1155/2017/7595642
    A gear-based knee joint is designed to improve the performance of mechanical-type above-knee prostheses. The gear set with the help of some bracing, and bracket arrangement, is used to enable the prosthesis to follow the residual limb movement. The motion analysis and finite-element analysis (FEA) of knee joint components are carried out to assess the feasibility of the design. The maximum stress of 29.74 MPa and maximum strain of 2.393e-004 are obtained in the gear, whereas the maximum displacement of 7.975 mm occurred in the stopper of the knee arrangement. The factor of safety of 3.5 obtained from the FE analysis indicated no possibility of design failure. The results obtained from the FE analysis are then compared with the real data obtained from the literature for a similar subject. The pattern of motion analysis results has shown a great resemblance with the gait cycle of a healthy biological limb.
  16. Dawal SZ, Zadry HR, Azmi SN, Rohim SR, Sartika SJ
    Int J Occup Saf Ergon, 2012;18(4):461-72.
    PMID: 23294660
    This paper presents an anthropometric database of high school and university students from Kuala Lumpur, Malaysia. Forty-one high school participants (21 males and 20 females), 13-17 years old, and 143 university students (74 males and 69 females) took part in the study. Twenty-one static body dimensions were measured. The greatest mean differences in the anthropometric data between male and female high school students were found in the sitting elbow height. In addition, a comparison of anthropometric data of male and female university students showed that data for males and females were significantly different, except for buttock-popliteal length, sitting elbow height and thigh clearance. The primary aim of this study was to develop an anthropometric database that could be used as a primary reference in designing products, devices and equipment for ergonomic learning environments.
  17. Nguyen HT, Md Dawal SZ, Nukman Y, Aoyama H, Case K
    PLoS One, 2015;10(9):e0133599.
    PMID: 26368541 DOI: 10.1371/journal.pone.0133599
    Globalization of business and competitiveness in manufacturing has forced companies to improve their manufacturing facilities to respond to market requirements. Machine tool evaluation involves an essential decision using imprecise and vague information, and plays a major role to improve the productivity and flexibility in manufacturing. The aim of this study is to present an integrated approach for decision-making in machine tool selection. This paper is focused on the integration of a consistent fuzzy AHP (Analytic Hierarchy Process) and a fuzzy COmplex PRoportional ASsessment (COPRAS) for multi-attribute decision-making in selecting the most suitable machine tool. In this method, the fuzzy linguistic reference relation is integrated into AHP to handle the imprecise and vague information, and to simplify the data collection for the pair-wise comparison matrix of the AHP which determines the weights of attributes. The output of the fuzzy AHP is imported into the fuzzy COPRAS method for ranking alternatives through the closeness coefficient. Presentation of the proposed model application is provided by a numerical example based on the collection of data by questionnaire and from the literature. The results highlight the integration of the improved fuzzy AHP and the fuzzy COPRAS as a precise tool and provide effective multi-attribute decision-making for evaluating the machine tool in the uncertain environment.
  18. Nguyen HT, Dawal SZ, Nukman Y, Rifai AP, Aoyama H
    PLoS One, 2016;11(4):e0153222.
    PMID: 27070543 DOI: 10.1371/journal.pone.0153222
    The conveyor system plays a vital role in improving the performance of flexible manufacturing cells (FMCs). The conveyor selection problem involves the evaluation of a set of potential alternatives based on qualitative and quantitative criteria. This paper presents an integrated multi-criteria decision making (MCDM) model of a fuzzy AHP (analytic hierarchy process) and fuzzy ARAS (additive ratio assessment) for conveyor evaluation and selection. In this model, linguistic terms represented as triangular fuzzy numbers are used to quantify experts' uncertain assessments of alternatives with respect to the criteria. The fuzzy set is then integrated into the AHP to determine the weights of the criteria. Finally, a fuzzy ARAS is used to calculate the weights of the alternatives. To demonstrate the effectiveness of the proposed model, a case study is performed of a practical example, and the results obtained demonstrate practical potential for the implementation of FMCs.
  19. Pai YS, Yap HJ, Md Dawal SZ, Ramesh S, Phoon SY
    Sci Rep, 2016 06 07;6:27380.
    PMID: 27271840 DOI: 10.1038/srep27380
    This study presents a modular-based implementation of augmented reality to provide an immersive experience in learning or teaching the planning phase, control system, and machining parameters of a fully automated work cell. The architecture of the system consists of three code modules that can operate independently or combined to create a complete system that is able to guide engineers from the layout planning phase to the prototyping of the final product. The layout planning module determines the best possible arrangement in a layout for the placement of various machines, in this case a conveyor belt for transportation, a robot arm for pick-and-place operations, and a computer numerical control milling machine to generate the final prototype. The robotic arm module simulates the pick-and-place operation offline from the conveyor belt to a computer numerical control (CNC) machine utilising collision detection and inverse kinematics. Finally, the CNC module performs virtual machining based on the Uniform Space Decomposition method and axis aligned bounding box collision detection. The conducted case study revealed that given the situation, a semi-circle shaped arrangement is desirable, whereas the pick-and-place system and the final generated G-code produced the highest deviation of 3.83 mm and 5.8 mm respectively.
  20. Mousavi M, Yap HJ, Musa SN, Tahriri F, Md Dawal SZ
    PLoS One, 2017;12(3):e0169817.
    PMID: 28263994 DOI: 10.1371/journal.pone.0169817
    Flexible manufacturing system (FMS) enhances the firm's flexibility and responsiveness to the ever-changing customer demand by providing a fast product diversification capability. Performance of an FMS is highly dependent upon the accuracy of scheduling policy for the components of the system, such as automated guided vehicles (AGVs). An AGV as a mobile robot provides remarkable industrial capabilities for material and goods transportation within a manufacturing facility or a warehouse. Allocating AGVs to tasks, while considering the cost and time of operations, defines the AGV scheduling process. Multi-objective scheduling of AGVs, unlike single objective practices, is a complex and combinatorial process. In the main draw of the research, a mathematical model was developed and integrated with evolutionary algorithms (genetic algorithm (GA), particle swarm optimization (PSO), and hybrid GA-PSO) to optimize the task scheduling of AGVs with the objectives of minimizing makespan and number of AGVs while considering the AGVs' battery charge. Assessment of the numerical examples' scheduling before and after the optimization proved the applicability of all the three algorithms in decreasing the makespan and AGV numbers. The hybrid GA-PSO produced the optimum result and outperformed the other two algorithms, in which the mean of AGVs operation efficiency was found to be 69.4, 74, and 79.8 percent in PSO, GA, and hybrid GA-PSO, respectively. Evaluation and validation of the model was performed by simulation via Flexsim software.
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