1

DESIGN AND DEVELOPMENT OF CACAO MULTIPURPOSE MACHINE

FOR FIL-ESTATE FARM IN LIPA CITY, BATANGAS: BASIS FOR

PRODUCTIVITY IMPROVEMENT

A research study presented to the faculty of Industrial Engineering

College of Engineering Architecture and Fine Arts

Batangas State University

The National Engineering University

Alangilan, Batangas City

In Partial Fulfillment of the Requirements for the Degree

Bachelor of Science in Industrial Engineering

Abanes, Joshua C.

Castillo, Khryss Jerome O.

De Guzman, Shyrica Mae D.

Dimalibot, Key Rold B.

August 2022
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CHAPTER I

THE PROBLEM AND ITS BACKGROUND

Introduction

This chapter presents significant information regarding the focus of the study. This

includes the background of the study that provides the context of the work, statement

of the problem, objectives of the study, conceptual framework, scope and limitation of

the study as well as the importance of the study.

Background of the Study

Cacao is developing as an important economic development engine in several

countries throughout the world. As cocoa beans' supply and demand imbalance

widens in recent years, the cacao industry has begun to acquire traction in domestic

and international markets, resulting in increased recognition for the industry (Bureau

of Plant Industry, 2017). It was projected that by 2020, global cocoa (Theobroma

cacao L.) demand is anticipated to be between 4.7 and 5 million metric tons (MT),

and production capacity would be 1 million MT short. Along with the rising demand

for the commodity, cocoa bean output has skyrocketed due to the rapid expansion of

small farmer participation. The increase in the global market is a chance for the

Philippines to expand its economy and create more jobs. Despite significant

competitive advantages, the Philippines' participation in the cocoa-chocolate

engagement is limited (DTI, 2017).

Cocoa was first introduced in the Philippines by the Spanish colonizers four

centuries ago. The country was the first in Asia to actively produce cocoa beans in the

latter part of the 1600s in San Jose, Batangas. By the 1950s, cocoa became a highly

profitable commodity as commercial cocoa farms and processing facilities were

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established. In 1980, cacao production expanded as tax incentives were offered by the

Philippine government for large scale investments, particularly in Mindanao where

the land and climate were suitable for the crop. (Peace and Equity Foundation, 2016)

The Philippine cacao industry is composed mostly of smallholder farmers who

supply dry cacao beans to the processors/manufacturers. Manufacturers are mostly

small to medium scale enterprises. Some of the larger players are into cocoa powder

and cocoa butter. Despite many competitive advantages in its geographic and climate

conditions and proximity to emerging consumer markets, the Philippines’ exports

remain low. It ranks 72nd in terms of exports and its global market share is less than

0.01%. (DTI, 2017)

However, the cocoa business in the Philippines is currently experiencing a

resurgence. After it has observed a rise in cocoa production volumes since 2006, the

government implemented policy measures to ensure the industry's continued growth

through R.A. 7900, also known as the High-Value Crop Development Program Act,

emphasizing the intensification of cocoa production as one of its priorities. (Peace and

Equity Foundation, 2016).

Farm work is hard work, and farm workers feel the results. Farm workers get

backaches and pains in the shoulders, arms, and hands more than any other health

problem. A third of the injuries that cause them to miss work are sprains and strains,

and a quarter are back injuries. These are also the most common causes of disability.

(Pinnacol, 2001)

Fil-Estate Farm is an agricultural farm that specializes in growing, harvesting,

drying and packing cacao beans that are traded locally and internationally. With a

wide land area planted with 10,000 cacao trees, they can harvest a total amount of
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three tons of cacao beans per season, having two harvest seasons per year. Having a

huge amount of harvested cacao beans, the farm relies solely on manpower effort

which makes the whole process (from harvesting to packaging) lasting from 15-20.

Fil-Estate Farm is a wholesaler type of business, which focuses on selling products

that is centered from their cacao farm such as cacao beans and tablea. It is a business

under Cariño Development & Management Corporation (CDMC) and was established

on October 16, 2014 and is located at Pangao Centro Lipa City, Batangas. Fil-Estate

Farm is comprised of ten workers, led by Mr. Marcial Namoca Jr. as the operational

manager and other significant workers who handles the labor on different processes.

Its’ operating days are during Monday to Saturday.

After conducting an interview with the operation manager and farmers of Fil-

Estate Farm, they said that determining the sizes and crushing the cacao is very

crucial for Fil-Estate Farm since it will determine if the beans have the potential to be

traded internationally or locally and it will give culinary products extra crunch for

various culinary recipes. The initial stage in the hand sorting and crushing process is

getting the sack of cocoa beans. The beans will now be spread out on the sorting table

and for crushing the beans will be spread into a laid-out sack. The farmers will start

sorting the cacao beans according to their classification on the other the farmers will

start rolling glass bottles to the cacao nibs in order to crush it and it is where the issue

is present. Beans of classes A and B are utilized for export, beans of class C are used

for local trade, and flat beans, which are discarded by farmers because they are seen

to be of worse quality, are also available. Farmers must spend a great deal of time

figuring out each classification of cocoa beans and powdering each nib, which slows

down output. The crushed cacao nibs will then be packed into a sealed bag as the last

stage of crushing and will then be sold to the market.

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In terms of the farmers' productivity, it can take two people up to one and a half

hours to manually sort one sack, or 50 kg, of cocoa beans. On the other hand, the

human method of grinding would require two people and take up to seven hours for

every 10 kg of cacao beans. The farm has the capacity to physically sort five sacks of

cocoa beans and grind ten kilograms of cacao beans per day. The researchers can see

how the procedure might be improved with the use of this data.

The farmers from the Fil-Estate Farm show symptoms of discomfort in areas such

as the; left and right shoulder, upper and lower back, left and right upper arm, left and

right forearm, left and right wrist, hip, left and right thigh, left and right knee, and left

and right lower leg discomfort, which, according to the Cornell Musculoskeletal

Discomfort Scale, places them at high risk. These symptoms are revealed in the

researchers' initial interviews with the farmers. According to the assessment, a

decrease in farmers' output could lead to another problem with their current process of

sorting and crashing of cacao beans.

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Figure 1. Process Flowchart of Cacao Beans Sorting

Figure 1 shows the process flow chart of cacao beans manual sorting. The first step

is getting the sack of cacao beans then pouring it into the sorting table. After that, the

workers will be sorting the cacao beans based on its classification. The final step in

the process is putting the sorted cacao beans into its designated storage.

The current process of cacao beans sorting in Fil-Estate Farm will be the basis of

the researchers to design and develop cacao beans multi-purpose machine that would

help them to reduce the time it consumes especially during the process of manually

sorting the cacao beans , reduce the body discomfort experience by the workers due to

awkward positions and repetitive motions during the said process and increase the

productivity of the workers.

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Figure 2. Process Flowchart of Cacao Beans Crushing

Figure 2 shows the process flow chart of cacao beans manual crushing. The first

step is getting the sack of cacao beans then pouring it into the crushing table. After

that, the workers will be rolling the glass bottles to the cacao nibs until it become fine

powder. The final step in the process is putting the crushed cacao beans into its

designated storage.

The current process of cacao beans grinding in Fil-Estate Farm will be the basis of

the researchers to design and develop cacao beans multi-purpose machine that would

help them to reduce the time it consumes especially during the process of manually

sorting the cacao beans , reduce the body discomfort experience by the workers due to
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awkward positions and repetitive motions during the said process and increase the

productivity of the workers.

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Figure 3. Body Discomfort Map (Standing)

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Figure 3 depicts the body's discomfort map when standing and the

assessment's findings using the Cornell Musculoskeletal Discomfort Questionnaires

(CMDQ). The CMDQ involves self-rating of the frequency, severity and work

interference of the MSD on three scales across 20 body parts. The responses given on

the frequency, severity and work interference scales can be used in computations as

percentages or can be given weights. On the frequency scale, the frequency of

experiencing MSD in the past work week is rated across the following anchors:

‘Never’, ‘1–2 times last week’, ‘3–4 times last week’, ‘Once every day’ and ‘Several

times every day’ with weights of 0, 1.5, 3.5, 5, and 10, respectively. On the severity

scale, the severity of the experienced MSD is rated across the following anchors:

‘Slightly uncomfortable’, ‘Moderately uncomfortable’ and ‘Very uncomfortable’ with

weights of 1, 2, and 3, respectively. On the work interference scale, the interference of

the experienced MSD with ability to work is rated across the following anchors: ‘Not

at all’, ‘Slightly interfered’ and ‘Substantially interfered’ with weights of 1, 2 and 3,

respectively. The answers of the workers were analyzed by getting the mean of the

responses given on the frequency, severity and work interference scales. By

multiplying the above frequency score by the discomfort score by the interference

score, we are able to get the total score and use the percentage formula to display the

fraction of the frequency of the responses and determine the percentage or level of

pain or discomfort of the workers.

According to the legend or color depiction, each bodily part's potential risk

and the necessary steps are indicated. A minor risk (1% - 20%) is indicated by the

color green, and no action is necessary. Yellow denotes a low risk (21% - 40%) , but

it also suggests that a change may be required. The orange color, on the other hand,

carries a medium risk (41% - 60%) of future research and change. Last but not least,
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the red color denotes a high-risk situation (61% - 100%), and immediate action is

needed.
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Figure 4. Hand Discomfort Map

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Figure 4 depicts the body's discomfort map of farmers for left and right hands and

the assessment's findings using the Cornell Musculoskeletal Discomfort Questionnaires

(CMDQ). The CMDQ involves self-rating of the frequency, severity and work

interference of the MSD on three scales across hand parts. The responses given on the

frequency, severity and work interference scales can be used in computations as

percentages or can be given weights. On the frequency scale, the frequency of

experiencing MSD in the past work week is rated across the following anchors: ‘Never’,

‘1–2 times last week’, ‘3–4 times last week’, ‘Once every day’ and ‘Several times every

day’ with weights of 0, 1.5, 3.5, 5, and 10, respectively. On the severity scale, the

severity of the experienced MSD is rated across the following anchors: ‘Slightly

uncomfortable’, ‘Moderately uncomfortable’ and ‘Very uncomfortable’ with weights of

1, 2, and 3, respectively. On the work interference scale, the interference of the

experienced MSD with ability to work is rated across the following anchors: ‘Not at all’,

‘Slightly interfered’ and ‘Substantially interfered’ with weights of 1, 2 and 3,

respectively. The answers of the workers were analyzed by getting the mean of the

responses given on the frequency, severity and work interference scales. By multiplying

the above frequency score by the discomfort score by the interference score, we are able

to get the total score and use the percentage formula to display the fraction of the

frequency of the responses and determine the percentage or level of pain or discomfort of

the workers.

According to the legend or color depiction, each bodily part's potential risk and

the necessary steps are indicated. A minor risk (1% - 20%) is indicated by the color

green, and no action is necessary. Yellow denotes a low risk (21% - 40%) , but it also
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suggests that a change may be required. The orange color, on the other hand, carries a

medium risk (41% - 60%) of future research and change. Last but not least, the red color

denotes a high-risk situation (61% - 100%), and immediate action is needed.

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Objectives of the Study

This study aims to design and develop a cacao beans multi-purpose machine for

Fil-Estate Farm in Lipa, Batangas to improve the sorting and crushing process of

cacao beans. Specifically, the study seeks to meet the following objectives:

1. To identify and evaluate the contributing factors to the problems the Fil-Estate

Farm are currently facing.

2. To determine the necessary specifications for designing a multi-purpose machine

for cacao beans while considering the following.

2.1 Filipino Anthropometric Measurements

2.2 Machine Requirement

2.3 Materials

3. To propose three (3) design alternatives for the cacao bean’s multi-purpose

machine while considering the given requirements and factors.

4. To conduct a trade-off analysis to identify the best design alternatives.

5. To develop the prototype of the chosen design alternative of cacao beans multi-

purpose machine for Fil-Estate Farm in Lipa, Batangas

6. To evaluate the effectiveness of the developed cacao beans multi-purpose machine

in terms of:

6.1 Efficiency of farmers

6.2 Productivity of farmers

6.3 Ergonomic Factors

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Conceptual Framework

For the objective of the study to be attained, a research paradigm was developed as

shown in this section:

INPUT OUTPUT
Knowledge/Data
Requirements
 Presently used PROCESS
method for crushing Identification of the
and sorting of cacao requirement in terms of:
beans
 Engineering Design  Sorting and Crushing Multi-purpose Cacao
 Ergonomic Process Beans Machine
 Material Requirement
concepts
 Design Specification
 Engineering Design  Worker’s Reduced pain and
 Trade-off Analysis Anthropometry
 Work Study and discomfort scores
Measurement Designing alternatives and indexes.
of Cacao Beans multi-
Design Requirements and purpose machine.
Consideration Increase the productivity
Through trade-off analysis,
 Selection of design alternatives are of workers
Materials and evaluated, and the best
Specifications design alternative is chosen.
 Cost of Materials Fabrication of the selected
and Design design alternative.
 Sketch-up
Execute a pilot test and
Hardware Requirements analyze the results.
 Fabrication Shop
 Material Resources

Figure 5. Conceptual Framework of the Study

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As shown in Figure 5 are the principles that are intended to be addressed in order

to pursue the study. Knowledge requirements like the present method for crushing and

sorting of cacao beans and knowledge of different engineering design and concepts

such as work study and measurement, ergonomics, and trade-off analysis are

essential. In addition, mastery with various ergonomic assessment tools like Cornell

Musculoskeletal Discomfort Questionnaires (CMDQ). The evaluation and guide to

assess the discomfort of the workers in the farm will be provided. The basis of the

proposed multi-purpose machine will be the collected data of anthropometric

measurements from the workers. The software that will be used to design the

proposed multi-purpose machine is Sketch-Up, it is a software that offers professional

quality design and modeling. Moreover, the specification of materials, availability and

cost will be collected for the input phase.

Furthermore, the process phase includes the analysis and evaluation of the existing

process in crushing and sorting of cacao beans in terms of cycle time, risk factors and

various machines. The collected data will be worked out by the researchers through a

sequence of methods and tools for designing and developing the semi-automated

machine. The use of the trade-off analysis will be key to the evaluation of the best

option requirement for the design that meets the requirements. As soon as the design

is determined, the development of the design will be done.

The following step is to perform evaluation and pilot tests concerning hazard

factors and productivity. Finally, an output will be a Multi-Purpose Cocoa Machine

for the Fil-Estate Farm that is presumed to be more productive and safer to operate.
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Significance of the Study

The findings of the study carried out by the researchers were very important for the

following:

To the workers of Fil-Estate Farm, the cacao bean’s multi-purpose machine will

be a great help to the workers to increase their productivity. Also, it will ensure the

workers' health and safety

To Fil-Estate Farm, with the help of designing and developing a cacao beans

multi-purpose machine, the study will enhance the workers' existing work

performance and decrease danger factors.

To the researchers, they will be able to learn more about the field of their study.

The research will act as a learning environment and a great chance for them to apply

the knowledge and abilities they have acquired about industrial engineering concepts.

To the readers and future researchers, the study will be used as a guide for

developing concepts and projects of a similar nature in other fields. This study will

also act as a resource for comparable studies and a manual for anyone who wish to

conduct their own research.

To the Industrial Engineering Department, the study will demonstrate

understanding and application of relevant industrial engineering concepts. The study

will also demonstrate how the university's cultivated knowledge helped the students

become globally competent and productive.

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To Batangas State University, the study will be a valuable contribution to the

organization that is globally ready and competitively productive to help further

research and grant fostered knowledge from the university.

Scope and Limitations of the Study

This study primarily focuses on designing, developing, and evaluating a multi-

purpose machine for processing of cacao beans in effort to increase worker

productivity and reduce worker discomfort. To identify the true root of the workers'

discomfort, an assessment of the work process and the workers is made, taking

ergonomics design concerns into consideration.

The study is limited to the design and development of a cacao beans multi-purpose

machine and an early assessment of the machine's effectiveness for Fil-Estate Farm in

Lipa City, Batangas. Furthermore, future machine redesign and maintenance are not

considered in this study.

Definition of Terms

The following terms were defined conceptually and operationally to better

comprehend the contents of this research.

Anthropometric Measurements. It is the non-invasive quantitative measurements

of the body (Kiel J. Casadei K, 2021). In this study, the anthropometric measures

of the workers who will be taken into account when designing the suggested multi-

purpose machine were taken into consideration by the researchers in this study.

Cacao Beans. Cacao beans are the agricultural product used to make chocolate.To

make chocolate, the beans are harvested, fermented, and dried, and then they’re

roasted, peeled, and ground into a smooth cacao mass. The purest chocolate is
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cacao mass, plus sugar. (“Dame Cacao”,2019). In this study, it is one of the

objectives of the researchers is to develop an ergonomic standard machine for the

cacao beans.

Cornell Musculoskeletal Discomfort Questionnaires (CMDQ). A questionnaire

containing a body map diagram and questions about the prevalence of

musculoskeletal aches, pain, or discomfort in 18 regions of the body.

("Musculoskeletal discomfort in production assembly workers"- Kristjan Jansen,

2017). In this study, it was used by the researchers as a means of determining the

discomfort of the workers in their bodies.

Discomfort. Discomfort can be physical or psychological and is characterized by

an unpleasant feeling resulting in a natural response of avoidance or reduction of

the source of the discomfort. (“The Differentiation Between Pain and Discomfort:

A Concept Analysis of Discomfort”- Shelly Ashkenazy, 2019). In this study, it was

one of the reasons that affects the performance of the workers of Fil-Estate Farm.

Multi-purpose Machine. Multi-purpose machine tool as we call it is a machine

that is made especially for the small-scale industries where labors working has very

little technology where performs their work quickly and efficiently without the

hassle of using different machines for performing different operations on work

piece (Dassault Systèmes SE, 2020). In this study, it is the expected final output of

the workers for the study.

Musculoskeletal Discomfort. Musculoskeletal pain affects bones, joints,

ligaments, tendons or muscles. An injury such as a fracture may cause sudden,

severe pain. (“Cleveland Clinic”, 2021). In related to this study, musculoskeletal

discomfort is one of the factors considered in making the machine.

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Musculoskeletal Disorders (MSDs). Musculoskeletal Disorders or MSDs are

injuries and disorders that affect the human body’s movement or musculoskeletal

system. (“The Definition and Causes of Musculoskeletal Disorders” - Matt

Middlesworth ,2022) In this study, this term helps the researchers to identify what

are the disorders and injuries the workers have, by the help of it we can identify

what are the causes and possible effect of this injuries to our body.

Pain. Pain is an unpleasant sensory and emotional experience associated with, or

resembling that associated with, actual or potential tissue damage. (“International

Association for the Study of Pain”, 2020). In this study, it was also one of the

reasons that affects the performance of the workers of Fil-Estate Farm.

Posture. It is the position in which we hold our bodies while standing, sitting, or

lying down. Having a better posture is beneficial in the correct alignment of body

parts supported by the right amount of muscle tension against gravity. Without

posture and the muscles that control it, we would simply fall to the ground.

(https://acatoday.org › Patients › Health & Wellness Information). In this study, it is

one of the factors that is needed to consider in order to achieve efficient results.

Productivity. It is the quintessential indicator of efficiency in any production

system where it seems it has become a norm in bibliometrics to define research

productivity as the number of publications per researcher, distinguishing it from

impact (Giovanni Abramo & Ciriaco Andrea D’Angelo, 2014). In this study,

productivity is one of the factors that is used as a solution to improve the farm's

performance.

Trade-Off Analysis. It refers to the approach that combines foresight analysis and

tools from the relevant discipline to evaluate strategic decisions under high level of
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uncertainty (Antle and Valdivia, 2021). In this study, the researchers used trade-off

analysis to be able to determine the best multi-purpose machine for the study.

Cause and Effect Diagram. It is known as a graphical tool for displaying a list of

causes associated with a specific effect. The graph organizes a list of potential causes

into categories by using a fishbone diagram or an Ishigawa diagram.

(https://www.sixsigmadaily.com/cause-and-effect-diagram). In this study, the

researchers use fishbone diagram to determine the other causes of MSD to the farmers

and shows the different categories of problem causes. The most common categories

used are the manpower, machines, materials, environment, measurement, and process.
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CHAPTER II

REVIEW OF RELATED LITERATURE

This chapter presents the reviewed literature and studies which are found relevant

in developing the framework of the study and in making the research clearer to the

reader. The references were gathered from the works of professional authorities as

well as the unpublished research papers that were deemed relevant in the conduct of

this study.

Conceptual Literature

Multi-purpose machine is a tool built specifically for small-scale companies with

laborers working. It was a machine that does all the job quickly and effectively

without requiring the inconvenience of utilizing numerous machines. Like any other

machines or equipment that is used by the workers within an organization, the multi-

purpose machine should be ergonomically fit to its users to lessen the discomfort and

have a comfortable experience while using it. However, having a poorly designed

machine can cause discomfort to the users since they are forced to adapt it in their

daily working conditions.

When it comes to work-related tasks that frequently bring discomfort to the

muscles, joints, and ligaments, musculoskeletal problems are indeed the major

complaint of the human body. This occurs when the conditions necessary for the work
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that the worker is given to perform are incompatible. Numerous musculoskeletal

problems can be attributed to poorly constructed machines for a variety of reasons,

including distinct psychosocial risk factors in addition to physical pressures.

Inappropriate equipment and tools used in a work situation can be linked to issues like

working dissatisfaction and stress brought on by pressure and a heavy workload

(Korhan, 2019).

Risk factors associated with musculoskeletal disorders among gemstone polishers

in Jaipur, India Gemstone polishing is a highly repetitive and strenuous job which

may lead to musculoskeletal disorders (MSDs) among workers. Evaluation of

working posture recommended further investigations and immediate changes in

working habits of gemstone polishers to avoid serious harm and physical damage.

Gemstone polishers in Jaipur are at high risk of developing MSDs in different body

regions. Sustaining a non-neutral working posture for a long duration is a major risk

factor in the current work setting (Das D et al., 2018).

Working in an awkward position is ineffective, according to the Ergoplus website.

Operating in your "comfort zone" is encouraged by the ergonomics approach, which

helps you operate more effectively and precisely while reducing discomfort. Reduce

any extra or pointless motions whenever you can. It's critical to get rid of needless

force demands and unnatural postures when this isn't an alternative. The technique of

ergonomics enhancement lowers ergonomic risk factors and enhances worker-job

connection.

Thus, cited by Berlin & Adams (2017), to identify what needs to be addressed first

and get rid of the high rating risk, many techniques and screening tools are utilized to

evaluate a design. Different methods are used to examine a worker's posture in

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relation to the tools, equipment, and workstation that they utilized during the

performance of duties: RULA and REBA. Both approaches serve different purposes,

and their application depends on the circumstances in which they are most

appropriate. RULA is more appropriate for usage when doing demanding tasks

involving the hand and arm. However, REBA is used to quantify the intense work that

the entire body performs. Nevertheless, both methods concentrate on a particular

posture that forces the worker to work for an extended period, regularly work in

uncomfortable positions, and adopt postures that need a lot of muscle movement.

Considering the identification of issues through observations and interviews, the

necessary steps will be taken to increase worker comfort while executing their jobs.

Research Literature

A study entitled, “A Review on Ergonomics in Agriculture. Part I: Manual

Operations” (L. Benos et al, 2020), Among the non-fatal occupational illnesses

appearing in farm workers, MSDs seem to be the most widespread. Repetitive lifting

and moving of heavy loads, prolonged trunk flexion (also called stooping), intensive

hand work, and working in awkward postures of wrist and trunk are tasks associated

with the main risk factors regarding the reported MSDs. Remarkably, low back pain is

recognized as the most prevalent musculoskeletal disorder that the agricultural

workforce suffers from, in both developed and developing countries. In fact, repetitive

and sustained stooping is the primary risk factor for low back pain. The risk factors

associated with the MSDs during different agricultural tasks have been extensively

investigated in the literature; for example, in the harvesting of fruit and sorting of tree

nut crops, climbing ladders meet the burden of bearing heavy loads, repetitive cutting,

and excessive reaching.

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(Amanda F. N et al., 2020) of his study entitled “The Relationship of Repeat

Movement and Work Posture Hands Position to The Event Of De Quervain's

Tenosynovitis Syndrome in Coffee Bean Sorting Workers” stated that, repetitive

movements, hand posture, direct trauma, and joint inflammation are risk factors that

can cause DQT. In the plantation sector, especially coffee sorter workers who are

tasked with manually sorting coffee beans using workers' hands continuously and for

long periods of time can cause workers to experience pain complaints on the body

parts of workers, especially the fingers to wrists, workers can thus be at risk of

experiencing DQT. De Quervain's Tenosynovitis Syndrome (DQT) is a type of

Occupational Disease in the group of Musculoskeletal Disorders which is

characterized by inflammation of the wrist side in the thumb, precisely on the tendon

of the musculus extensor polis brevis and musculus abductor pollicis longus due to

trauma or loading that is too heavy, with typical symptoms such as pain, numbness,

and tingling in the thumb to the wrist.

Also, in the study entitled “Risk Factors for Musculoskeletal Disorders in Manual

Harvesting Farmers of Rajasthan” (Jain, et al., 2018), Manual harvesting is a

physically demanding occupation with several work-related issues in which

musculoskeletal disorders (MSDs) happen most commonly. The risk factors for

MSDs among manual harvesting farmers are not investigated properly in low and

low-middle-income nations. Therefore, a study among 140 farmers of Rajasthan,

India was carried out through the usage of Nordic Musculoskeletal Questionnaire and

the Rapid Upper Limb Assessment (RULA) technique to identify ergonomic risks. χ2

analysis was used to find the relationship between the MSDs and various factors.

Also, logistic regression methodology was applied to get the most influencing factor

for MSDs in different body regions. The lower-back, fingers, shoulders and
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wrists/hands were the body parts in which more than 50% workers reported MSDs.

MSDs in one or more body regions were found to be associated with age, daily

working in farms, farming experience, gender, hand dominance and perceived work

fatigue. The age was majorly associated with MSDs in all body regions except the

shoulder and neck as per the outcome of logistic regression. The outcome of RULA

grand score had been found higher than or equal to 5 in 92% of the farmers which

give directions for further research and changes.

Based on the article entitled “Ergonomic Task Analysis for Prioritization of

Work-Related Musculoskeletal Disorders among Mango-Harvesting Farmers”

(Boriboonsuksri et al., 2022), This paper proposes a mixed ergonomic tool analysis

algorithm to prioritize work-related musculoskeletal problems. This study is a cross-

sectional study assessing the prevalence of work-related musculoskeletal disorders

(WMSDs) with associated risk factors among 14 male mango harvesting farmers (all

right-handed) with the mean age of 52.28 ± 7.75 years. Four tasks following mango-

harvesting processes were analyzed: mango harvesting, mango transporting, mango

size sorting, and mango weighing and transporting to the truck. The perceived

physical exertion while working on a mango-harvesting farm was based on the Borg

CR-10 with a modified Standardized Nordic Questionnaire. Physical risk level due to

awkward posture was evaluated by the Rapid Upper Limb Assessment (RULA), and

risk due to whole-body posture in association with the level of WMSDs risk was

evaluated by the Rapid Entire Body Assessment (REBA) score sheets. The subjective

feelings of fatigue and posture analysis were normalized and combined using the

theorem of power superposition to establish the fatigue effective index (FEI) for

determining priorities to solve ergonomics-based task problems. This study indicated

clearly that WMSDs are highly prevalent in mango-harvesting farmers, whereas the
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highest prevalence of WMSDs was reported in the right shoulder, right upper arm and

lower back. The result provided the FEI of mango-harvesting farmers, ranked as

follows: size-sorting task, weight-lifting task, harvesting task, and transporting task.

The authors concluded that mango size sorting should be the first task to be improved

to resolve the muscle fatigue problems among male mango-harvesting farmers.

In the study entitled “Design and Development of Cocoa Pod Breaking and

Beans Extraction Machine” (Josué et al., 2019), The cocoa bean damage is one of the

main problems of the pod breaking process. Beans damage, separation of beans from

mixtures and scrap shells are the main problems related to cocoa pod breaking. The

objective of this work is to determine the physical and mechanical properties of cocoa

pods required for the design of the equipment, dimension of the different parts

constituting the equipment and put in place a geometric representation of the

equipment that can rise the quality of cocoa products. Some physical and mechanical

properties of the pod were obtained through experimental study. Different varieties of

cocoa were initially subjected to compressive forces along the lateral axis. After that,

they were set on a test bench to break the pods one after the other with a mass of steel

at different heights. Thus, the average breaking strength and the moisture contents of

each variety of cocoa pods were determined. This fracture resistance of the cocoa pod

was measured in terms of average force, deformation and toughness at the cocoa shell

fracture, and cocoa pod stiffness (rigidi-ty). The modulus of rigidity of the pod was

obtained from measurements of force and deformation. From the physical and

mechanical properties of the pod, we modeled a suitable machine. This designed

machine severs the poles and ruptures the pods facilitating extraction of the beans on

the hulls. It can be assembled and disassembled easily, reliably and without any risk
 29

for the user. Consequently, it might be used by all cocoa producers in order to

optimize the process of cocoa pod breaking.

In the study, “Effect of simultaneous implementation of ergonomic interventions

and management decisions on reduction of musculoskeletal disorders and

improvement of work postures between Milk sector workers of dairy factory”,

(Karimi, Azim, et al, 2020). The CMDQ is a suitable tool for the evaluation of work-

related musculoskeletal disorders. The ergonomic evaluation uses a quick exposure

check posture analysis method. This methodology allows assessing worker exposure

to a wide range of risk factors for musculoskeletal disorders.

Also, based on an article, “Relationships between Cornell Musculoskeletal

Discomfort Questionnaire and Online Rapid Office Strain Assessment

Questionnaire”, (Shariat, et al. 2018). There are various kinds of questionnaires to

determine the musculoskeletal discomfort experienced by workers. The Nordic and

Cornell are the most common questionnaires used for this purpose. The Cornell

questionnaire was used to determine the level of pain among office employees in

response to rest breaks and ergonomic modifications. Musculoskeletal discomforts,

particularly pain severity among office employees, can be collected by the Cornell

questionnaire shown to be a valid and reliable tool. Nonetheless, since the ability of

Rapid Office Strain Assessment to detect the discomfort severity among workers has

not been authenticated there are concerns that the Cornell scores’ results may differ

from the ROSA.

Another study entitled, “Anthropometric measurements among four Asian

countries in designing sitting and standing workstations; cited from Anthropometric

measurement of Filipino manufacturing workers”, (Sådhanå, 2018). The Filipinos

 30

anthropometric database includes measurements for standing, sitting, hand and foot

dimensions, breadth and circumference of various body parts obtained from 1805

workers, with a majority (77%) being below 30 years. This is the first ever

comprehensive anthropometric measurement of Filipino workers in the country which

is seen as a significant contribution to the Filipino labor force who are increasingly

employed both in the local and international market.

Synthesis

The researchers were efficient in providing improved concepts and connections

between the study and related literature of “Design and Development of Cacao Beans

Multi-Purpose Machine for the Fil-Estate Farm in Lipa, Batangas.” Also, the studies

support researchers in getting a better knowledge and identifying the research

outcome.

The study of L. Benos et al. (2020), reported the MSD’s experienced by the

farmers because of the awkward postures, specifically lower back pain during the

manual operations in agriculture. In order to learn more about the discomfort that the

farmers and caretaker encountered while working, the researchers consult with them.

The most common response is lower back pain. The uncomfortable postures caused a

lot of farmers to feel this kind of agony. The distinction between the two studies is

that the present study took into consideration the farmers' muscle exhaustion while

they used their hands and arms to sort and grind produce, whereas the earlier study

merely paid attention to fruit harvesting, repetitive cutting, and excessive reaching.

The study presented by Amanda F. N et al. (2020), aimed to determine the

causes of DQT or known as the De Quervain’s Tenosynovitis Syndrome that is an

occupational disease of wrist inflammation occurring in the working conditions such

 31

as repetitive movements in sorting. Regarding the farmers' concerns during the sorting

procedures, the initial study is comparable to the current study. Because they were

constantly manually sorting, the majority of them suffered injuries and joint irritation

while carrying out the sorting activities.

The study of Jain et al. (2018), states that manual harvesting is a physically

demanding occupation with several work-related issues regarding the musculoskeletal

disorders experienced by the farmers. Similar to the current study, it involves

conducting interviews with farmers to identify the frequent issues that arise in real life

scenarios. The majority of the farmers, it was found, complained of body discomfort

and lower back and hand muscular tiredness. These elements have an impact on the

farmers' productivity in carrying out the necessary procedures or stages. The two

studies differ in that the former study placed more emphasis on the risks of manual

harvesting while the latter study is more concerned with the manual sorting and

grinding procedures carried out by cocoa bean farmers.

The study of Boriboonsukri et al. (2022), is also connected to the present study

because it conceptualized the ergonomic tool analysis algorithm to prioritized work-

related musculoskeletal problems. The risks of dealing with these issues at work were

taken into consideration in the current study. Similar to how most farmers collect

mangoes and then carry them in trucks while keeping uncomfortable postures, the

farmers at Fil-Estate Farm harvest cacao beans and then transport them in the usual

way with similar physical efforts. The two studies are different in that the present

study concentrates on work-related musculoskeletal issues that arise during the sorting

and grinding of cacao beans, whereas the other study emphasizes on the harvesting

and transportation of mangoes. The Standardized Nordic Questionnaire was thus

employed in both researches to ascertain the issues faced by the farmers under these
 32

working circumstances. They differ in collecting and gathering information and data

wherein the present study had a personal interview to the caretaker of the farm and

workers of the Fil-Estate Farm while the related study conducted survey

questionnaires

The research of Josué et al. (2019), and the current study are identical in how

the proposed machine was developed and how the cacao beans were crushed. The

current study considered the ergonomic requirements that will be suitable in the

creation of the proposed multi-purposed machine, whereas the previous study

emphasized on the physical and mechanical features of the cacao pods needed in the

breaking process. While the proposed multi-purpose machine will be working on the

sorting and grinding process of the cacao beans for the farmers of the Fil-Estate Farm

in Lipa Batangas, the developed machine of the prior study is simple to construct and

disassemble.

The study of Karimi, Azim et al. (2020) states that CMDQ is the a top

parameter to analyze work-related muscoloskeletal disorders. Since the CMDQ is the

ergonomic tool that the researchers use to gauge the risk factor that the farmers

encounter when processing the cocoa beans, it is relevant to the current study. The

difference between the two research is that the current study utilized the CMDQ to

measure risk factors among farmers who work in the cocoa bean processing industry,

whereas the other study focuses on assessing risk factors among dairy factory workers

in the milk sector.

The study of Shariat, et al. (2018) refers CMDQ to be a valid and trustworthy

technique for measuring worker discomfort. This study is relevant since the CMDQ is

often regarded as the finest tool for assessing workers' aches and pains. The two
 33

studies are different from one another since the present study's researchers only

employed the CMDQ as a tool to quantify workers' pain, but the earlier study also

considered the ROSA results when assessing the discomfort of office workers.

The study of Sådhanå (2018) reported that the Filipino Anthropometric

Measurement has made a significant contribution to the labor force of Filipino

Workers. The previous study employed Filipino Anthropometric Measurement to

increase employment of Filipino workers locally and internationally, the current study

used it to analyze the standards on the output that will be generated for the well-being

of its future users.

To conclude, the conceptual and research literature has significantly improved

the researcher's findings and conclusions in terms of generalizing ergonomic and

engineering concepts that are important to the development of cacao beans multi-

purpose machines for the Fil-Estate Farm in Lipa Batangas.

 34

CHAPTER III

RESEARCH METHODOLOGY

This chapter presents the method of the study including the research design,

subject of the study, data gathering instrument and procedure as well as the statistical

treatment of all the data that are used in the design development of cacao bean multi-

purpose machine for Fil-Estate Farm at Lipa, Batangas.

Research Design

The researchers will use a design and development method. It is the systematic

study of design, development and evaluation processes with the aim of establishing an

empirical basis for the creation of instructional and non-instructional products and

tools and new or enhance models that govern their development. To enhance the

status and well-being of workers in Fil-Estate farm, the study will use a design and

development method. The design and development method is the most appropriate
 35

choice for the study since it focuses on creating novel insights and concepts that were

essential to its success.

In order to learn more about the procedure and current machinery that is currently

used in cacao bean sorting and crushing, the researchers will also provide the owner

and workers a questionnaire. The researchers will conduct workplace observations to

have a better grasp of the procedures. The problems that will emerge during the

process will be noted and analyzed. The Ergonomic Assessment Questionnaire will be

used by the researchers to examine workplace activities. The researchers will next

develop three improved cacao bean multi-purpose machine design alternatives based

on the physical characteristics, process, materials, and cost of the worker. The

researchers will employ a trade-off analysis and systematic elimination approach to

ascertain the importance of each criterion and determine the best design alternative for

a cacao bean multi-purpose machine. The best design option with the highest score

will be chosen, and fabricated.

Subject of the Study

The four farmers of Fil-Estate Farm who are working on the sorting and crushing

of cacao beans will serve as the study's main subject. Because they fall under the

chosen specialty, and have a direct connection to the study, the aforementioned

individuals had a significant role in the study.

The farm's owner is also a subject of the study because they will provide the

researchers with all the data they need. Four farmers, two panelists, a chairman, and

one fabricator make up the eight respondents for the trade-off questionnaire.

The researchers are going to evaluate the difficulties faced by the farmers during

the crushing and sorting of cocoa beans. Additionally, they took into account the
 36

farmers' anthropometric measurements and obtained their opinions and assessments of

the intended use and components of the cacao bean multi-purpose machine to be

developed.

Data Gathering Instrument

To come up with the most effective design for the cacao bean's multipurpose

machine, the researchers are going to use a variety of data collection tools. The

gathering of pertinent data greatly aids researchers in producing high-quality work

that is both effective and efficient.

The researchers will conduct an interview with the owner together with the

workers of Fil-Estate Farm who witnessed every step of the process and collect data

and information. It will help the researchers in identifying the underlying causes of

issues and challenges that arise with the farm's current systems and machinery to

produce the best design that would optimally fit the workers who will be involved in

the sorting and crushing process. The researchers will also take ergonomic

considerations and safety concerns into account in connection to anthropometric

measurements.

The researchers will also use a survey questionnaire as a tool to gather additional

information. Cornell Musculoskeletal Discomfort Questionnaire will be utilized by

the researchers as it is a great help in detecting the worker’s MSD. The questionnaire

is very easy to administer among workers and it gives a picture of MSD with detailed

history of site and frequency of the discomfort. For the initial assessment, using the

Cornell Musculoskeletal Discomfort Questionnaires, the researchers will assess the

body discomfort maps of the workers. The CMDQ is a 54-item survey that asks about

musculoskeletal pain, discomfort, and soreness in different body areas and includes a
 37

body chart. Farmers will use it to assess musculoskeletal pain in their bodies. The

CMDQ scoring rules will be followed in calculating the musculoskeletal discomfort

score to determine the rate of discomfort and quantify the discomfort level.

All of the questionnaires and evaluation tools shall be examined and confirmed by

a team of experts before the essential data for the study are collected. Comments and

suggestions will be assessed in order to improve the data collection tool. After

determining the reliability values for all of the used equipment and personnel, the

researchers will move on to the actual data collecting.

Filipino Anthropometric Measurements will also be in use as a basis in order to

come up with a machine design that is suitable for the workers of Fil-Estate farm.

Anthropometry is the science of measurement and the art of application that

establishes the physical geometry, mass properties, and strength capabilities of the

human body. The uses of anthropometry in the workplace include to evaluate body

measure and posture distances to reach control. Consequently, Filipino

Anthropometric Measurements is a data that considers measurement and dimensions

of the human body and it focuses mainly on the Filipino people as its main factor.

To maintain the significance and reliability of the study, the researchers are going

to collect supporting data through publications, scholarly works, the internet, journals,

and other research materials for information on the problem to be investigated and

proposed.

Data Gathering Procedures

The researchers will reach out to the head worker/farmer upon the approval of the

request to visit their cacao farm and gather information. After approving the request,

the researchers will proceed on interviewing the workers and will also observe the
 38

existing manual process of cacao bean sorting. In developing design alternatives for

the cacao bean multipurpose machine, the researchers will review some existing

designs and machines that are found on the internet, published and unpublished

studies, development studies, and experts, and fabricator's advice. The materials and

the possible cost of the semi-automated machine were then reviewed and evaluated.

Consequently, to understand the numerous tasks at Fil-Estate Farm, the researchers

will distribute survey questionnaires to the workers. The Cornell Musculoskeletal

Discomfort Questionnaires will be utilized by the researchers as an ergonomic

assessment tool to investigate and evaluate the workers' work-related injuries or

discomfort (CMDQ). Additionally, it will show how varied degrees of discomfort

affect an employee's ability to work. To comprehend the procedure and workstation

better, the researchers also examined the workplace. The problems will be developed

during the process shall be quickly identified. The researchers will then develop three

concepts or alternatives for the multipurpose machine for cacao beans. The

researchers will consider a range of metrics and factors, such as material selection and

specifications, material cost, and ergonomic considerations, while conceiving the

multiple alternatives.

The researchers will also employ trade-off analysis and the systematic elimination

approach to evaluate each criterion's importance and identify the optimum design

alternative. After the researchers have been identified the ideal design alternative, the

design with the highest score among the alternatives will be fabricated.

Statistical Treatment

The researchers will use the formula of mean, weighted mean, and percentage. The

mean and weighted means were utilized to identify the result of the Cornell
 39

Musculoskeletal Discomfort Questionnaires, and this also incorporates for the other

ratings in the different design criteria in trade-off analysis as maximin decision,

imprecise designer ranking table method, standard weighted sum method, systematic

elimination method was used to achieve a better analysis of all the data gathered. The

Anthropometric Measurement of Filipino was used to lie the anthropometric

measurement for the alternative design. To interpret the data gathered effectively, the

researchers made use of the following formula:

Mean. It was employed in this research to assess the level of pain or discomfort

surveyed per questionnaire items, and to interpret them.

∑x
µ=
n

Where:

ẋ = weighted mean 𝑛 = sample size

Percentage. It was also used to display the fraction of the frequency of the

responses and determine the percentage or level of pain or discomfort of the workers.

x
∑ ∗ 100
n

Where:

ẋ = weighted mean 𝑛 = sample size

Weighted Mean. It was used to see if there are significant differences between

two or more means.

∑f 1w 1
ẋ=
n

Where:
 40

ẋ = weighted mean 𝑤1 = weight t

𝑓1 = frequency 𝑛 = sample size

Discomfort Score = Frequency * Discomfort * Interference

Output (Currect Process)

Efficiency of the Farmers =
Output (New Process)

Changes in Productivity of the Productivity ( New)−Productivity (Old)

Farmers = ∗100 %
Productivity (New)