Trolley rack design for tea factory workers in Indonesia based on anthropometric approach

Trolley rack is a material handling that significantly affects production productivity in Indonesian Tea factories. The design of this tool needs to consider the anthropometric approach. This study raises the problem of the dimensions of the trolley racks used in the industry without thinking about the anthropometric approach. Of the twenty-two trolley rack operators, 92.5% of workers experienced back pain when operating the equipment. This problem has an impact on musculoskeletal disorders (MSDs), which causes a decrease in effectiveness and workers. The REBA and Nordic Body Map Questionnaire methods are used to obtain optimal operator posture analysis related to the redesign of the trolley rack. Five anthropometric dimensions of a comfortable trolley rack were obtained, including shoulder height (SH), standing shoulder width (STW), leg length (FL), foot width (FW), and hand grip width (HGW). The final anthropometric dimensions of this tool are SH = 126 cm, STW = 33 cm, FL = 11 cm, FW = 13 cm, and HGW = 5 cm. Using new trolley racks in this study increased productivity by 80%.