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Ergonomics can help boost productivity on plantations

by Dr. N. Yogaratnam, Consultant, National Institute of Plantation Management

Ergonomics is all about human resource management and little else. Taking rubber plantations in Sri Lanka as the test-case, it is discussed how high productivity cannot be achieved if you ignore the human elements.

Ergonomics is a multi-disciplinary science that strives to achieve higher productivity that will lead to increased profitability by understanding the capabilities and limitations of the workers. Known as 'human factor engineering' in the US and as 'psychological engineering' in other parts of the world, it is, in fact, "the scientific study of relationship between man and his working environment with special reference to anatomical/physiological factors." And its objectives: To increase the efficiency of human activity by providing data which will enable informed decisions to be made.

Which, in effect, should enable the cost to be minimised, in particular by removing those features of design which cause inefficiency or physical disability.

It is also intended to create an awareness in industry of the importance of considering human factors when planning work, thereby making a contribution not only to human welfare but to the national economy as a whole.

The application of ergonomics on rubber plantations in Sri Lanka is both relevant and important, as these plantations still remain vital to the economy of the country. Rubber production in the country reached its peak in 1978 at 155,000 tonnes. But, various factors contributed to a steady decline in production over the past several years. The total production in 2003 was only about 95,000 tonnes.

Further, the annual average yields achieved in the past by most estates have been in the region of 900-1,000 kg per hectare, which is insufficient to maintain profitable operations if rubber prices do not continue to remain as attractive as at present. The estates should therefore aim to achieve an average yield of 2,000 to 2,500 kg/hectare/year.

Tapping efficiency

Several yardsticks are available in the industry for judging production efficiency and its effect on cost reduction. Among them, the most important is tapping efficiency, which represents the quantity of latex harvested per manday. Substantial differences in tapping could be due to several factors.

One major factor is the effective tapping time, that is the real time spent only on tapping and related activities. The next factor is the efficiency of the tapper (or, in other words, worker productivity).

Tapper productivity

Labour accounts for about 60 per cent of the total cost of production of rubber in Sri Lanka. Tapping cost, a major component of production cost, accounts for about 35-40%. And about 70% of the worker's time is spent on tapping.

Worker productivity is measured in terms of intake per tapper (IPT). On most plantations, the average IPT for a given year varies from 6 to 8 kg and the generally accepted norm is 7 kg with a provision for an incentive payment for more quantities at the rate of Rs. 6 a kg.

Several worker-related factors such as body weight, height, age, length of the arm, knowledge, experience, skill, besides civil status and education, are expected to influence tapper productivity. Factors relating to health and nutrition of workers are also known to influence productivity.

Household responsibilities of female workers with young children are also likely to adversely affect productivity.

Worker availability

Worker availability on estates is dependent on two main factors. The availability of workers who are willing to work on the estates and the frequency with which they report to work. The overall labour deficit today has been the result of a slow but steady decline, averaging about 4 per cent per year, over the last 10 years. The situation is likely to aggravate owing to more attractive alternative work being found by workers outside plantations.

The total rubber acreage in Sri Lanka is now around 161,000 hectares, out of which about 120,000 ha are in production (tapping). With the mean mature stand of 500 trees/ha and a tapping task of 300-350 trees per tapper, the total tapper requirement of the country would be about 72,000. But at present there is a shortage of skilled tappers which is in the region of 10 per cent, and a further 10 per cent of available tappers are unskilled. Hence an urgent need to look into tapper-related problems to improve labour productivity, turn-over and retention.

Time management

Tapping productivity may also be affected by time spent on tapping-related activities. In Sri Lanka, the official working day for agricultural labour is eight hours. This does not normally include the time that is spent in travelling to work.

Effective time management is a major factor in enhancing tapping efficiency. Tappers with experience, knowledge and developed skills and are regular at work are the most effective workers in terms of improving productivity.

To increase tapper productivity, estate profitability and minimise problems related to non-availability of skilled tappers, it may be possible to offer two tapping blocks of 300 trees/block to high-intake tappers (HITs). The effective tapping time under this system would be about 362 minutes which is still well within their working time of 480 minutes/day.

Such tappers may be able to start tapping at 6 a.m. and complete 2 blocks with a short break of 30 minutes for snacks at the work site (to be provided by the estate).

They may be provided with a battery operated lighting system if there is insufficient light for tapping and also work in uniformity.

Skilled and knowledgeable tappers may be more effectively employed by assigning them only tapping operation.

Sundry other workers can be used for other tapping-related activities such as latex collection from, say, 1,200 trees (2x2x300 trees) and transportation by vehicle and the like. This would save about 68 minutes of the productive time of the skilled tappers.

Management should ensure that there is no discrepancy between the actual latex intake and the weight indicated at the weighing point, which forms the basis for payment. This Loss of Recovery Double-Tapping arrangement may be compensated by the introduction of 'rain-guarding' technology.

As the IPT is significantly different between panels, allocation of high-productivity tapping fields to HITs is obviously desirable.

Absenteeism

Healthcare facilities should be given priority as illness is one of the major factors for absenteeism, which is negatively correlated with productivity.

Engagement of HITs in the proposed manner would lead to an acceptable tapping cost of Rs. 16.89 per kg.

This would include the wages of HITs, latex collection workers, cost of mid-day snack and of transport and uniform (as in the box). Emphasis should be placed on improved tapping skills in terms of angle, depth and length of tapping, to preserve the tree and to assure steady income.

This HITs take 21 more minutes than low-intake tappers (LITs) to complete the tapping task of 300 trees, but their standard in terms of length, depth and angle of tapping is superior to that of the LITs.

Benchmarking

Unskilled LITs have to be identified and given specialised intensive training to upgrade them to the level of HITs. Such training should include both human related factors and technical aspects such as knowledge and tapping skills.

This should be followed up with regular impact monitoring, evaluation and putting in place reporting systems to provide constant feedback to identify critical issues and constraints and provide solutions to improve their performance.

Skill development plans should be drawn up regularly to educate and develop the tapping skills of the new-generation tappers.

Adequate knowledge and skill developed by working regularly and alongside parents, may be further improved by means of systematic HRD programmes of HITs also, as it is possible to increase their intake to over 15 kg per 300 trees with improved human and technical strategies.

Incentives for trainees

In order to attract the younger generation, some incentives in the form of work uniform, snacks at worksite, change in designation, recognition of training programmes completed by awarding certificates, cash prizes for merit performance etc. should be offered.

Beside, curriculum of GCE (O/L) classes in schools in the rubber growing districts should include subjects that would provide some basic knowledge on rubber tapping, highlighting the importance and benefits of working as tappers.

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Replenishment of Humus in agricultural soils

Most of the present day agricultural soils lack organic matter commonly referred to as humus and the productivity has to be maintained by the application of expensive inorganic (chemical) fertilisers. The humus keeps the soil healthy and alive with soil microorganisms, retaining moisture and preventing leaching of plant nutrients. There is efficient absorption of nutrients by the plants in the presence of humus in the soil.

It is my view that the soil fertility can be better managed by a combination of methods of manuring, where a part of the nutrient requirement is supplied by inorganic fertilisers and the balance by organic (compost) manure, and green manure.

Lopping from gliricidia, dadap, accacia, ipil ipil and other green manure mulched on the soil surface and the compost and waste material from livestock forked into the soil become humus, but such material may not be available in adequate quantities in some of the farms.

Compost is a good soil conditioner and aerates the soil. Compost is very rich in minor plant nutrients. The major plant nutrients NPK is comparatively less in compost, in which case a large amount of compost per acre is necessary.

A readily available source of organic material for making compost is garbage available in plenty in the towns, which the local authorities very often find difficulty to dispose of.

In 1961 I worked for Major O.L.M. Lebbe, the proprietor of Balantota, Group, Nawalapitiya. Major had a practice of adding compost only to the pruned tea fields of his estate. When the fields reached the tipping state after pruning, the fields were forked and the compost and other ground litter were forked into the soil.

Major had a separate block of land closer to the Nawalapitiya town, where the garbage and the night soil of the town were brought and deposited and converted into compost there.

The State has subsidised the cost of urea fertiliser for the farmers from the 1st of May.

If the State can convert all the garbage into compost in the provincial towns, as did Major Lebbe in Nawalapitiya, such compost can be sold to the farmers in those areas and the quantity of imported fertiliser under the subsidy can be accordingly reduced and foreign exchange can thus be saved.

A lot of solid waste material like glass, tin, iron, etc. are found in the garbage and these will have to be separated before processing into compost.

These materials can be sold to the industrialists who can re-cycle and use them.

At present garbage is collected, transported and deposited as land filling, which adds to pollution and is a somewhat wasteful expenditure and the dumping sites are not easily available.

What I suggest above will solve this problem and there will be some income from the garbage. There are now farmers engaged in organic farming, because such produce fetch very good prices. Even tea is now cultivated in Sri Lanka organically for the export market.

In organic farming, no chemical fertiliser, pesticide and weedicide are used and as such there is no chemical residues in the crop.

As fertiliser, they use compost or recycled organic material or green manure.

There will be a good demand for compost, if a project could be started to convert town garbage into compost.

It is hoped that this letter will attract the attention of the Minister of Agriculture and arouse his interest to produce compost to supply the farmers countrywide.

- A.C. de Silva

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Rambuttan - the mellow fruit

Rambuttan (Nephelium lappaceum) is one of the most delectable fruits of the East, and the lofty tree is native to the Malay Archipelago (group of islands). The name 'Rambuttan' is derived from the Malay word 'Rambut' meaning hairy.

The Portuguese who were ruling the maritime settlements of Sri Lanka, since their arrival in 1505, were supposed to have introduced this most delicious fruit to the island. Rambuttan plantations were opened at Malwana, on the right bank of the Kelani River, which was one of their fortified defensive strongholds against the offending armies of King Sitavaka Rajasinha. Malwana was the usual residence of the Portuguese Captain-General Don Jeronimo de Azevedo, who got down the seeds from Malaya.

Even today, Malwana is famous for quality Rambuttan (Peni-Rambuttan), the sweet variety of the red type, so attractive to look at when the trees are laden with huge bunches. The pericarp has a hairy coat and the endocarp is a gelatinous white aril which is edible. In the best variety (Mas-Rambuttan), the aril an be removed from the seed easily unlike other varieties.

The trees thrive well where the rainfall is evenly distributed, but a moist and a hot climate is preferred for luxuriant growth.The trees do not grow beyond 1,000 feet in elevation above sea level. The edible part is rich in Vitamin C and Phosphorous, but has a slight acid taste. The tree is less susceptible to serious and persistent diseases, wind damage and attack by pests.

Countries famous for Rambuttan are Java, Malaysia, Philippines, India, Singapore and other adjacent tropical countries in South-East Asia. The fruits grown in Sri Lanka are used for local consumption.

Now is the Rambuttan season. We can see heaps of nice-looking red coloured fruits kept for sale by vendors, who sell them at competitive prices, ranging from Rs. 2.00 a fruit to Rs. 1.00 each, depending on quality and taste. The fruit is said to be heaty to the body, in view of its high calorific value, and in some, it causes allergy.

- Aryadasa Ratnasinghe

www.Pathmaconstruction.com

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