Redesign of a Cable Tie Tool, Enhancing Ergonomics in Assembly Work

Abstract

The Base Module Line (BML) at Volvo Truck’s manufacturing plant in Tuve has the highest frequency of tightening and cutting cable ties, resulting in repetitive tasks for assembly operators. This repetitive work has led to work-related injuries, particularly pain and discomfort in the hands, wrists, shoulders, and back. Therefore, Volvo Truck wants to investigate if an existing electric cable tie tool can be redesigned to meet the ergonomic requirements at the BML. This Master’s thesis aimed to develop an electric cable tie tool that can tighten and cut cable ties on the BML while ensuring ergonomic interaction for the operators. Before creating a redesign proposal for the reference tool, it was important to understand the current situation and investigate all stakeholders’ requirements and desires for a new tool. Data was gathered, summarized, and analyzed from interviews with operators and ergonomists and observing the work environment. Using a combination of traditional product development and reverse engineering methods, a prototype was then created. The final prototype was primarily produced using 3D-printed parts, integrating mechanical and electrical components from the reference tool. Key outcomes include ergonomic improvements when using the prototype, particularly in altering operators’ work postures, which reduced strain in the hand and wrist areas. Although the prototype is not fully functional, it effectively addresses the ergonomic challenges, contributing to a more comfortable working environment for the assembly operators.