ANALYZE PHASE
Phase three of five progressive phases
PHASE SUMMARY
The main goal of this phase is to perform analysis on the data obtained during the Measure Phase. The analysis performed involved ergonomics, time, money, stress, and deflection. The team also determined the root causes of problems occurring with the process and ensured that the design of choice would meet the customer requirements.  Additionally, the team identified sources of variation and methods of improvement, prioritized opportunities to improve the process, and determined the necessary resource level. The team began building a prototype of the final design.
ROOT CAUSE ANALYSIS
In the Analyze Phase, the team utilized data obtained during the Measure Phase and began a root cause analysis to determine the causes of various problems. The root cause of most problems with the current method of harvesting was found to be from the physical stresses placed on the workers. The root causes of most problems with the previous year’s mechanism was due to the fact that the device did not have the necessary height capabilities and was difficult to transport. It was important that the team identified these root causes in order to address them in the design of the improved Oil Palm Harvester.
FINITE ELEMENT ANALYSIS
The team also utilized data from the Measure Phase to compare the improved design to the current methods and previous year’s design. The first analysis was a Finite Element Analysis which determined that the device would undergo similar stresses to the previous year’s mechanism, but would also have double the height capabilities. Although the deflection was higher for the improved mechanism, there was doubt in the validity of the previous year’s deflection calculations. The number from their calculation is not even enough to account for the tolerances within the poles to allow them to slide within one another. Also, the deflection of the improved design is relatively small when one considers the 40 feet height that the device will reach. Even so, the team used that information to determine features that would be added to mitigate and offset the deflection of the device, such as safety brackets, safety stoppers, added legs, and leveling pins.
ERGONOMIC ANALYSIS
The team also performed an ergonomic analysis with the current method of harvesting and with the assembly of the previous year’s prototype. Each of those processes were found to have a Rapid Upper Limb Assessment score of seven. This means that the tasks involved expose the workers to ergonomic risks, and the tasks need to be investigated and changed immediately. The biggest risk factors that contributed to such a high score was that the arms of the workers had to be at least 45 to 90 degrees above horizontal with the neck extended back to perform the work. The improved mechanism is able to retract down to a smaller size so the workers do not need to reach or look as high up when using it. As are result, the RULA score for the improved mechanism was four which means to investigate further and change soon. Although this RULA score is not as low as it potentially could be, it is still better than the current standard. Also, the team worked to make the device more ergonomic throughout the Improve Phase improving the ease of transport. This included the implementation of additional handles and wheels.
TIME AND MONEY ANALYSIS
The team also performed a time and money analysis on the device. In terms of time, the device was comparable to the current method of cutting down the Oil Palm fruit. The improved mechanism takes about five and a half minutes to harvest Oil Palm fruit, whereas the current method requires five to eight minutes. In addition to being comparable in harvesting time, the improved mechanism reduces variation in the harvesting process to allow for consistent harvesting times. Since the time is not reduced to cut down the fruit, there are no reduction of labor costs. The improved mechanism though, will reduce the amount of workers who are out or working less productively due to an injury from harvesting. It will also make the job more attractive to potential workers and require less prerequisites such as skill and strength to harvest the fruit than the current process requires.  This could help to offset the current labor shortages in the Oil Palm harvesting industry.
