Background: Flaps of the corrugated box folded inversely while manual packing of goods initiative this will cause tearing of the box at creased positions.
Objective: To avoid tearing, it is required to twist each box along creased positions as soon as it is manufactured and in wet condition due to liquid gum application.
Methods: To apply and evaluate the effect of Low-Cost Automation on labor productivity and labor fatigue for corrugated boxes flaps twisting. Low-Cost Automation solution is applied to overcome low labors' productivity and excessive labors' fatigue problems in the manual box twisting work. Productivity need analysis is performed to identify the key productivity measures. Three automated mechanisms are developed for box stopping, clamping, and twisting activities.
Results: Reduction in labors muscular efforts requirement is confirmed through surface electromyography technique. It is observed that the average actual time required for twisting one box reduced from 34 seconds to 17 seconds, and labor productivity almost doubled. The muscular efforts required for twisting of flaps of the boxes are reduced significantly.
Conclusion: The developed low-cost automation solution is unique and found worthy for small scale corrugated box manufacturers.
Keywords: Electromyography; labor fatigue; labor productivity; low cost automation (LCA); mechatronics; productivity need analysis (PNA).