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The Impact of Poor Assembly Ergonomics on Product Quality: A Cost-Benefit Analysis in Car Manufacturing
Abstract
The study aimed at analyzing the relationship between assembly ergonomics, assemblability (“ease of assembly”), and product quality and at quantifying these relationships in economic terms. This was in order to better to support the development of more ergonomic product and assembly solutions, particularly at early stages of the car development process. The assembly of 24,443 cars was studied for 8 weeks in an assembly plant and for another 16 weeks as factory-complete vehicles. The results show increased risks for quality errors of 3.0 and 3.7 times and total action costs that were 8.7 times and 8.2 times higher for high and medium physical load assemblies compared to low physical load assemblies for 55 tasks assessed. © 2009 Wiley Periodicals, Inc.
... Simultaneously, companies need to offer production staff a sustainable work life. There has been shown a strong correlation between poor ergonomics and both productivity losses and quality deficiencies, e.g., in the form of assembly errors [1]. Hence, poor ergonomics in the production lines can result in major costs for companies. ...
... Hence, poor ergonomics in the production lines can result in major costs for companies. In the research of Falck et al. [1] the term ergonomics represents the human well-being perspective of the ergonomics definition. Ergonomics, or human factors, is defined as the scientific discipline concerned with the understanding of interactions among humans and other elements of a system, and the profession that applies theory, principles, data, and methods to design in order to optimize human well-being and overall system performance [2]. ...
Recently the concept of Industry 5.0 has been introduced, reinforcing the human-centric perspective for future industry. The human-centric scientific discipline and profession ergonomics is applied in industry to find solutions that are optimized in regard to both human well-being and overall system performance. It is found, however, that most production development and preparation work carried out in industry tends to address one of these two domains at a time, in a sequential process, typically making optimization slow and complicated. The aim of this paper is to suggest, demonstrate, and evaluate a concept that makes it possible to optimize aspects of human well-being and overall system performance in an efficient and easy parallel process. The concept enables production planning and balancing of human work in terms of two parameters: assembly time as a parameter of productivity (system performance), and risk of musculoskeletal disorders as a parameter of human well-being. A software demonstrator was developed, and results from thirteen test subjects were compared with the traditional sequential way of working. The findings show that the suggested relatively unique parallel approach has a positive impact on the expected musculoskeletal risk and does not necessarily negatively affect productivity, in terms of cycle time and time balance between assembly stations. The time to perform the more complex two-parameter optimization in parallel was shorter than the time in the sequential process. The majority of the subjects stated that they preferred the parallel way of working compared to the traditional serial way of working.
... As noted by [27], training in industrial skills is critical to nations' economic development and competitiveness. Their effectiveness reduces the number of errors made by industrial workers, which can have catastrophic consequences for the product and total production costs [28]. Meanwhile, performance metrics used in VR tools make it possible to identify mistakes made by the trainee, and on this basis, their weaknesses are indicated [18]. ...
... As noted by [27], training in industrial skills is critical to nations' economic d ment and competitiveness. Their effectiveness reduces the number of errors mad dustrial workers, which can have catastrophic consequences for the product and to duction costs [28]. Meanwhile, performance metrics used in VR tools make it po identify mistakes made by the trainee, and on this basis, their weaknesses are in [18]. ...
(1) Background: The article presents the results of research carried out as part of one of the project’s tasks, aiming to develop training scenarios for selected workstations related to the operation of passenger rail transport. The article aims to present the results of a training experiment to verify the effectiveness of the developed training scenario for conductors regarding lift operations for people with disabilities. (2) Methods: The study used an analysis of the execution times of individual training tasks, accompanying observation, face-to-face interviews, and a comparative analysis of the effectiveness of various training strategies. The research was carried out following the developed five-stage research procedure. (3) Results: The obtained research results confirm the benefits of using virtual reality in training conductors and allow for determining the most effective training strategy. The measurements of the execution times of individual training operations made it possible to identify the tasks in the training program that were the most time-consuming or characterized by highly diversified execution times. (4) Conclusions: Based on the research, it was possible to develop recommendations regarding the changes that should be introduced in the training tool to better adapt to the real conditions of service operations. The effectiveness of using this form of training in relation to the improvement of a selected group of employees was confirmed.
... Achieving consistent, timely and high-quality assembly of complex products is paramount for manufacturers to ship value to customers. Although a well-established part of the threat to quality is attributable to high physical loading [1][2][3][4], cognitive overas well as underloading [5] may result in lowered task performance, possibly leading to increases in costly assembly errors, time consumption and frustration. Working conditions that can distract, confuse, overload or even bore assembly workers throughout a full working day may threaten successful assembly, as well as the well-being of the assembly workers and their willingness to remain in the profession. ...
... Early phases of product and production design, where design-and manufacturing engineers are involved, are the most optimal development stages for proactive ergonomics action [2]. At the same time, early intervention is a very cost-effective way to ensure good working conditions for the workers. ...
In paced assembly lines, cognitive processing is required from assembly workers to perform correct and timely assembly of complex products with varying specifications. This interview study involving 75 industrial assemblers, design- and manufacturing engineers explores how assemblers’ cognitive performance is influenced by multiple factors within the contexts of product design, production setup and assembly. Our results indicate that both positive and negative effects on assemblers’ cognitive performance can stem from task design, timing, physical loading demands, extrinsic motivation factors, teamwork and the assembly “interface” design. Among design- and manufacturing engineers, two mindsets emerged: (i) a product-centred mindset relying on assemblers having sufficient experience, knowledge, and assembly instructions, (ii) an assembler-focused mindset characterised by an iterative and collaborative development process to ensure easy-to-assemble solutions, and avoid errors, delays and costly re-work. Despite organizational differences and conditions between the companies that took part in the study, the results are largely consistent.
... The strong link between quality errors and high ergonomic risks has been demonstrated by other studies (Falck et al, 2010, Falck and Rosenqvist, 2014, Fritzsche et al., 2014. As a result of the studies carried out in Volvo car production plant in 2010, a strong relationship was found between inappropriate ergonomic conditions and quality defects. ...
... As a result of the studies carried out in Volvo car production plant in 2010, a strong relationship was found between inappropriate ergonomic conditions and quality defects. Of the 352 quality problems recorded in the production phase of three new car models, 23.5% were associated with ergonomic problems (Falck et al., 2010). In another study conducted in the automobile manufacturing plant, 47 assembly tasks were analyzed. ...
There are many studies discussing the issue of ergonomics in the context of sick leave and social expenditures. However, there are fewer studies linking production ergonomics with other factors such as quality and efficiency. It would be useful to discuss production ergonomics in a wider context. The study was carried out as a pilot study in a factory where a built-in oven was produced. The aim of the study is to show that there is a relationship between production ergonomics and the product quality produced in the factory. In the study, retrospective 20-week production line data were analyzed. As a result of the analysis, a series of quality errors were selected and the assembly tasks associated with these errors were determined. Aassembly tasks are classified by the company's Occupational Safety and Health Specialist as ergonomically appropriate or not ergonomically suitable for operators. When the difference between the number of errors related to the ergonomic categories is examined, it is found that there are three times more errors in ergonomically inappropriate tasks compared to ergonomically appropriate tasks. The work to be done to make the ergonomically inappropriate tasks suitable, the time plan and the responsible people were determined. The results of the study showed that there is a relationship between product quality and production ergonomics. The calculations in the study showed that the error rate would decrease by 90% in ergonomically optimized tasks; thus, business management has made a positive decision to invest in equipment to the relevant workstations. In return for the investment cost in the study, resources are used for value generating works and an increase in the number of correctly produced products is guaranteed.
... WMSD and WMSI refer to painful conditions affecting the muscles, tendons, and nerves, during regular and repetitive work activities (Liu et al., 2023). Moreover, there is a relationship between poor ergonomics and losses in terms of productivity and assembly quality (Falck et al., 2010). All the negative effects of poor working postures increase costs for manufacturing companies. ...
The analysis and correction of working postures is an essential practice in industry. Discomforting postures and repetitive tasks could cause strain, fatigue, musculoskeletal disorders, pains, and injuries, reducing worker productivity. Several normative standards provide tools and methods for observation, evaluation, and solving critical ergonomic situations. The workstation assessment often requires the study of the actions and postures of each operator related to each task and each repetitive cycle. In the context of assembly line workstations, a common task is the material picking from storage shelving. The ergonomic evaluation of shelving for lineside temporary parts storage is focused on the layout, location of each part container, and picking frequencies. An ergonomic evaluation in the shelving design phase could reduce the risk of repetitive and poor working postures, producing benefits for the operators.The paper proposes a parametric optimization tool based on a Genetic Algorithm to reduce the ergonomic risks related to the picking phase from light shelves employed in assembly lines. RULA and OWAS methods are used to perform the ergonomic evaluation of different configurations of shelves during the optimization analysis. As a test case, the design of a light shelving is proposed considering the time and assembly cycle of fitness bikes.
... Several case studies conducted in the manufacturing industry context have shown measurable improvements in productivity and quality through HF/E (e.g., De Looze et al. 2010;Falck et al. 2010;Tompa et al. 2010;Zare et al. 2016). In relation to this, Falck and Rosenqvist (2014) highlight the importance of competent HF/E specialists' involvement in business development processes. ...
Human factors and ergonomics (HF/E) as a concept has been narrowed down to individual health and well-being and therefore excluded from business education as irrelevant. Such conceptualization neglects the synergistic goals of HF/E to simultaneously optimize individual well-being and overall system performance. Drawing on a systematic review of the literature on HF/E, we showcase that employee well-being and productivity are rarely integrated into the strategic management of firms in manufacturing industries. Moreover, the narrow interpretation of HF/E limits the possibilities to make human-centric decisions and, consequently, the ability to obtain various benefits that would contribute to productivity and firms’ better overall performance. The rapid growth of new technologies and the digitalization of work particularly require the highlighting of HF/E in managerial planning and the strategic renewal of the firm. Contradicting frequent erroneous expectations, the integration of new technologies or digitalized processes does not necessarily lead to better outcomes for the firm or individuals working in it. The benefits can only be reached if human-system interaction is designed and managed appropriately. To close the knowledge gap on HF/E in the strategic management of the firm, we present a framework that can be used when teaching (future) managers to integrate HF/E into strategy and its implementation. This framework can inform educators about the essential points of HF/E in strategy work and help to lead classroom discussions on this topic. As a result, our contribution helps address Sustainable Development Goal (SDG) 8—Decent work and economic growth.
... For decades, the manufacturing industry has witnessed a continuous rise in automation levels [1]. Despite this transition, manual assembly remains a cost-effective option in various manufacturing domains, such as automotive, electronics, and aerospace manufacturing [2], [3], [4]. Owing to their inherent adaptability [5], manual assembly systems can meet the needs of increasing product complexity and variety required by flexible manufacturing systems [6]. ...
Human operator-induced assembly errors affect the quality of car manufacturing. Understanding the factors influencing assembly errors is critical for quality improvement. The sequence of assembly operations, a factor markedly affecting cognitive load, remains largely understudied. We aimed to assess the effect of changing the sequence of assembly operations on error rates through four field experiments conducted in a car manufacturing plant. The parts (and errors) under study were child lock labels (missing labels), sunroofs (missing bolts), windshield wiper arms (loose bolts), and armrests (wrong selection). Parts were chosen based on data from quality records, and they represent different scenarios regarding the sequencing of assembly operations. Minitab was used to conduct the statistical test for two proportions at a significance level of 0.05. The experiments ran for a period varying from 9 to 25 weeks (22292 to 138456 cars). All four experiments exhibited significant differences in the proportion of errors. MODAPTS cycle-time calculations revealed no negative effect of assembly sequence variations on productivity. The study findings show that changing the assembly operation sequence can reduce the error rates, possibly due to the intermediary effect in reducing the operator’s cognitive load. Overall, realizing quality improvement requires optimizing the assembly operation sequence in terms of time and productivity while considering its possible impact on error rates.
... Designers need to consider it from the beginning, otherwise, it can lead to problems: e.g., parts that are difficult to reach or install or require a complex assembly process (Dul and Neumann 2009). Overall, inadequate assembly considerations lead to a negative impact on production and are not cost-free to correct afterward (Whitney 2004;Falck et al. 2010). So, implementing DFA in the early stages helps optimize assembly, reducing the number of components, and simplifying the design (AlGeddawy et al. 2017). ...
The success of a product in the market is largely defined by the quality of design decisions made during the early stages of development. The product design requires designers to balance multiple objectives such as functionality, cost, and user satisfaction, while addressing the challenges posed by increasing product variants and customization demands. To tackle these challenges, one approach is to structure a comprehensive model that incorporates design for assembly (DFA) guidelines during the formulation of product architecture in the conceptual phase of development. While numerous strategies have been proposed in the literature, information is often scattered, making it difficult for readers to gain a comprehensive understanding of the topic. This paper systematically reviews the role and impact of DFA in product development, consolidating and presenting the information coherently. The review provides an overview of the methods developed, along with their potential benefits and limitations. A common framework is identified that defines the structure of the models, helping designers integrate assembly consideration into their design processes, thus reducing assembly time, cost, and complexity. The framework describes the operational setting, including the domain and context in which models operate, and offers a classification of possible methods and desired outputs. Additionally, the review identifies the industry in which case studies have been most frequently presented, and the software used to facilitate the process. By connecting with such a framework, future models can be created following a structured approach, and existing models can be classified and upgraded accordingly.
... Moreover, bad ergonomics has shown to also have a huge impact on production quality. Studies report that on average 80% of tasks with medium or high ergonomic loads in automotive production results in quality problems [6] [7]. Therefore, making assembly operations ergonomically sound is crucial in order to ensure sustainable workplace design, quality and productivity [8]. ...
Musculoskeletal disorders (MSD) as a result of bad workplace design and ergonomics are one of the leading causes of work-related injuries, this is especially true for assembly workers within the manufacturing industry.This paper investigates the possibilities to implement an automated ergonomics evaluation assessment into a Digital Human Modeling (DHM) software to evaluate workplace design for assembly tasks within manufacturing. A benchmarking and screening process was conducted to identify the most suitable ergonomics assessment method to be implemented into the DHM software. Furthermore, a pilot implementation, using Industrial Path Solution (IPS) Intelligently Moving Manikin (IMMA) as the referenced DHM software, was held with China Euro Vehicle Technology (CEVT) to solidify the results of the integrated function. This paper showcases that automated ergonomics assessment methods can, successfully, be integrated into a DHM software.KeywordsDigital Human ModelingErgonomicsSoftwareSimulationsVirtual Verification
... Neglecting ergonomic considerations in conventional ALBP can lead to indirect costs in the long term, such as absenteeism and medical or healthcare expenses. Additionally, Falck et al. (2010) reported that in the short term, disregarding ergonomic factors can result in costs for the car manufacturing industry, including health and safety expenses, productivity losses (e.g., line stoppages), and quality issues (e.g., scraps, reworks). Increased ergonomic risks can lead to chronic injuries, imposing significant costs on both organizations and society. ...
This comprehensive review paper presents the state of the art on assembly line balancing problems, with a specific focus on considering ergonomics aspects (Ergo-ALBPs) and providing insights into the emerging Industry 5.0 paradigm. Traditional assembly line balancing approaches often overlook ergonomic factors, which can lead to work-related injuries and long-term expenses for manufacturing systems. However, recent advancements have seen the integration of human factors and ergonomic (HFE) indicators alongside operational factors in optimization problems, aiming to prevent future ergonomic-related costs. Through a systematic review of the literature published from 2011 to 2022, this study analyzes 57 selected studies, examining their content on operational and ergonomics aspects individually and concurrently. Additionally, this paper highlights the significant implications of the Industry 5.0 paradigm in Ergo-ALBPs, emphasizing the importance of human-centered design, collaboration between workers and advanced technologies, and the challenges faced during implementation. The review also identifies research trends, gaps, and opportunities through comparative content analysis, keyword frequency analysis, and co-occurrence (co-word) analysis, offering valuable insights for future research in this domain. Keywords: Assembly line balancing problem, ergonomic risks, human factor, ergonomic assessment tools, Ergo-ALBP, Industry 5.0, worker-centric design. Results and views expressed in this publication are the sole responsibility of the authors and do not necessarily reflect those of CIRRELT. Les résultats et opinions contenus dans cette publication ne reflètent pas nécessairement la position du CIRRELT et n'engagent pas sa responsabilité.
... Furthermore, compared to the non-welding workers, a higher incidence of symptoms of musculoskeletal disorders in the cervical, dorsal, lumbar, wrists and hands were found among the welders (Lourenço and Luís, 2021). Since musculoskeletal disorders caused by these awkward postures (Salleh et al., 2021) are present quite often, several research has been conducted to measure the level of discomfort (Baek and Nam, 2021;Dinagaran et al., 2019;Fahzan bin Salleh et al., 2020;Falck et al., 2017;Falck et al., 2010;Keshavarz Panahi and Cho, 2016;Lowe et al., 2001;Suman et al., 2018). Panahi et al. (2021) also studied this critical issue to detect muscle fatigue and identify vulnerable muscles vulnerably (to musculoskeletal disorders) and proved that Recurrence Quantification Analysis (RQA) is an effective method for evaluation during tasks. ...
... The factors that were found are related to the automobile sector, especially for cars and there is a need to explore the sub-factors of each main factor that is mentioned in Section 2. Some researchers have attempted to find out the relations between two or three factors, such as ergonomics and product quality [24], [25], studying the relation of consumer willingness and their preferences to pay for new vehicle technology. We found few relationships between these factors and to date no study has been conducted on what type of sub-factors affect the main non-factors mentioned in Section 2. Therefore, a study should be carried out that does not only show the connection between different sub-factors but can also show the ability of each sub-factor to affect the other sub-factors for the ...
The success of a car in the market depends on visual as well as non-visual factors. Both these sets of factors influence the cognitive appeal of cars for potential buyers. Purchasing a car is not only about economic choices but also related to emotional, aesthetic, sensory responses to driving, kinship patterns, habitation, sociability, and functionality. This study aimed to identify the major non-visual factors of cars that affect the cognitive perception of buyers and estimate their importance relative to each other. A set of non-visual factors and their sub-factors were identified through a literature search and an open-ended survey among car owners. Many of the sub-factors had the same meaning and therefore these factors were grouped under twenty separate sub-factors. Then, these twenty sub-factors were analyzed by using the Decision-Making Trial and Evaluation Laboratory (DEMATEL) approach to evaluate the most influential sub-factors among the identified sub-factors. Six designers were involved in the analysis of the sub-factors through the DEMATEL approach. The results showed that the car’s brand value, cost, engine performance, reliability, and safety are the top five sub-factors. Outcomes of this study can be utilized by designers and top management people to understand the most influential factors affecting the cognitive behavior of consumers when purchasing a car. This understanding will help companies to design cars as per the requirements of consumers, which will ultimately lead to better profitability of these companies.
... Productivity and worker well-being often go hand in hand, because improving working conditions usually increases productivity [7][8][9][10]. However, sometimes the goals of productivity and well-being are at odds. ...
Usually, optimizing productivity and optimizing worker well-being are separate tasks performed by engineers with different roles and goals using different tools. This results in a silo effect which can lead to a slow development process and suboptimal solutions, with one of the objectives, either productivity or worker well-being, being given precedence. Moreover, studies often focus on finding the best solutions for a particular use case, and once solutions have been identified and one has been implemented, the engineers move on to analyzing the next use case. However, the knowledge obtained from previous use cases could be used to find rules of thumb for similar use cases without needing to perform new optimizations. In this study, we employed the use of data mining methods to obtain knowledge from a real-world optimization dataset of multi-objective optimizations of worker well-being and productivity with the aim to identify actionable insights for the current and future optimization cases. Using different analysis and data mining methods on the database revealed rules, as well as the relative importance of the design variables of a workstation. The generated rules have been used to identify measures to improve the welding gun workstation design.
... Academically, there have been attempts to link the relationship between ergonomic conditions, workloads, total action cost, and productivity in processes that involve human factors, such as manual welding [16][17][18][19][20]. The welding work in the enclosed space of a ship was analyzed by Lowe et al. [21]. ...
Welding, a key technology in the shipbuilding industry, is mostly performed by hand, owing to the complex structure and shape of production blocks. This manual welding requires a variety of working postures, which have become an important determinant of the worker’s workload and, consequently, assembly man-hours. Currently, major shipyards calculate welding man-hours by reflecting the welding factor, which is defined as the working time consumed in the welding process. A set of welding factors is known to be based on the accumulated experience in shipyards, whereas the verification or derivation process for these factors is not disclosed or available. This study proposed a method for quantitatively calculating work difficulty for welding positions based on the working posture in a process where the posture acts as an important variable. Standard welding positions reflecting the actual welding work at shipyards were established. A physiological assessment method was used to propose the physical welding factor by analyzing the measured muscle activity. The validity of the proposed method was verified by comparing the results of a musculoskeletal simulation package and shipyard welding factors. The proposed method can be readily applied to other fields in which workers’ physical activities are involved.
... Effective industrial training has always been paramount. Beyond the undeniable value of health and safety training, literature reports that the costs of fail-to-recall procedural tasks, for example in a production environment, are high and that errors can be catastrophic for the product and the overall production costs [1]. Similar shortcomings apply when errors occur beyond the production line, for example in the assembly of machinery or instalment of electronic components in the field of business or hard-to-access locations, such as offshore wind turbines or oil drilling rigs [2] [3]. ...
Virtual reality (VR) training offers the capability to industrial workers to acquire skills and address complex tasks by immersing them in a safe and controlled virtual environment. Immersive VR (IVR) training is adopted in many diverse settings, yet little systematic work currently exists on how researchers have applied it for industrial skills training and if it holds the potential to be applied remotely. In this review, 78 representative studies were analysed to answer three key questions: Is IVR an effective training method for industrial skills training? How is research in this field applied? And how can we make IVR training more effective and applicable for remote training? We can testify that IVR is a promising training method with high effectiveness scores. However, our analysis has uncovered several gaps in the application of IVR training, like the lack of learning theories in the design process and limited metrics beyond time and scores. Additionally, our review also exposed unexplored but intriguing avenues of research, like the utilisation of biosensors for users' data collection, haptics that increases realism and applications with remote training potential.
... Effective industrial training has always been paramount. Literature, reports that the cost for fail-to-recall procedural tasks in a production environment is high, and errors can be catastrophic for the product and the overall production cost [9]. Similar shortcomings apply * e-mail:unnik@btech.au.dk † e-mail:chinello@btech.au.dk ‡ e-mail:kkoumaditis@btech.au.dk when errors occur beyond the production line, for example, assembly of machinery or installation of electronic components in the field of business or hard to approach locations, like offshore wind turbines or oil drilling rigs [23]. ...
Effective industrial training has always been vital. Recently, theneed for robust, safe, repeatable and cost-effective digital applica-tions drove many industries to explore immersive technologies andespecially Immersive Virtual Reality (IVR) as a possible solution.In this paper, we depict three such cases, from the Danish industryand showcase the motivation of such adoption, technological anddesign characteristics, alongside perception of its applicability.
... In addition, time for the creation of assembly instructions can be decreased through automating this process with the help of AI. The proposed system will therefore reduce quality costs in all three areas ( Niedersteiner et al., 2015 ;Falck et al., 2010 ). ...
The aim of this paper is to present a conceptual approach to an augmented intelligence-based worker assistance system in manual assembly. This approach is designed to address current challenges in global value networks. We propose a self-learning multi-camera system that (1) provides augmented reality-based assembly instructions and (2) enables automated real-time in-process testing of complex manual assembly operations by using visual camera and CAD data, operational experiences and expert knowledge. As the proposed solution is targeted at enabling SMEs, cost-effectiveness is a main goal of the conceptual approach. Consequently, weak artificial intelligence is applied to realise the algorithmic chain subject to performance restricted hardware. The approach states a novelty in research and development and contributes to practical application in the field of augmented intelligence.
... However, in manufacturing domains where product complexity and variety present particular challenges, manual work remains a viable alternative. This is the case of such manufacturing domains as consumer electronics [3], aerospace manufacturing [4,5], combustion engine assembly [6], automotive manufacturing [7,8] and the production of industrial machines and tools [9,10]. Hence, for manual assembly to yield a final product of the appropriate level of quality, several operations must be executed properly. ...
Manual assembly operations are sensitive to human errors that can diminish the quality of final products. The paper shows an application of human reliability analysis in a realistic manufacturing context to identify where and why manual assembly errors occur. The techniques SHERPA and HEART were used to perform the analysis of human reliability. Three critical tasks were selected for analysis based on quality records: (1) installation of three types of brackets using fasteners, (2) fixation of a data cable to the assembly structure using cushioned loop clamps and (3) installation of cap covers to protect inlets. The identified error modes with SHERPA were: 36 action errors, nine selection errors, eight information retrieval errors and six checking errors. According to HEART, the highest human error probabilities were associated with assembly parts sensitive to geometry related errors (brackets and cushioned loop clamps). The study showed that perceptually engaging assembly instructions seem to offer the highest potential for error reduction and performance improvement. Other identified areas of action were the improvement of the inspection process and workers' provision with better tracking and better feedback. Implementation of assembly guidance systems could potentially benefit worker's performance and decrease assembly errors.
... Research has shown a clear relationship between poor ergonomics and productivity losses and quality deficiencies such as assembly errors, which incur significant costs for companies [1]. Hence, when designing factories and workstations or making other decisions that affect ergonomic conditions, it is important to proactively ensure proper ergonomic conditions for workers. ...
Simulations of future production systems enable engineers to find effective and efficient design solutions with fewer physical prototypes and fewer reconstructions. This can save development time and money and be more sustainable. Better design solutions can be found by linking simulations to multi-objective optimization methods to optimize multiple design objectives. When production systems involve manual work, humans and human activity should be included in the simulation. This can be done using digital human modeling (DHM) software which simulates humans and human activities and can be used to evaluate ergonomic conditions. This paper addresses challenges related to including existing ergonomics evaluation methods in the optimization framework. This challenge arises because ergonomics evaluation methods are typically developed to enable people to investigate ergonomic conditions by observing real work situations. The methods are rarely developed to be used by computer algorithms to draw conclusions about ergonomic conditions. This paper investigates how to adapt ergonomics evaluation methods to implement the results as objectives in the optimization framework. This paper presents a use case of optimizing a workstation using two different approaches: 1) an observational ergonomics evaluation method, and 2) a direct measurement method. Both approaches optimized two objectives: the average ergonomics results, and the 90 th percentile ergonomics results.
... Research has shown a clear relationship between poor ergonomics and productivity losses and quality deficiencies, e.g. due to assembly errors, which also causes large costs for companies [1]. In spite of the above-mentioned relationship, productivity, ergonomics and quality are commonly treated separately in factory, line and workstation planning. ...
There is a constant strive in industry to be competitive on the market, to manufacture with quality and productivity. At the same time, it is important to offer workers a sustainable work life. Research has shown a clear relationship between poor ergonomics and productivity losses and quality deficiencies, e.g. due to assembly errors, which also causes large costs for companies. In spite of the above-mentioned relationship, productivity, ergonomics and quality are commonly treated separately in factory, line and workstation planning. To improve the factory, line and workstation planning, make it more efficient, ergonomic and to improve quality this paper proposes a concept that enables line balancing that considers two parameters in parallel, assembly time and ergonomic load as well as add possibility for mathematical optimization. The concept has been developed in a participative and iterative process. Two software tools and a simulation platform, the digital human modelling tool IPS IMMA, the balancing tool AVIX and the optimization platform EPP, have been used to demonstrate the concept. An integrated solution is formed. The integrated demonstration tool shows promising results. The demonstrator provides the possibility to manually optimize ergonomics and time in parallel, a relatively unique functionality.
... These methods often ignore the duration of exposure to extended moderate risks in one task when a slight proportion of high-risk exposure is identified. Recent studies have shown that exposure to extended moderate risk factors might have a synergistic effect on exposure to risks [7]. ...
The study assessed the proportion of time in risky postures for the main joints of the upper limbs in a truck assembly plant and explored the association with musculoskeletal symptoms. Fourteen workstations (13 individuals) of a truck assembly plant were selected, and seven sensors were placed on the body segments of the participants. The sensors included tri-axial accelerometers for the arms and back, inclinometers for the neck and electro-goniometry for quantifying flexion/extension of the right and left hands. The proportions of time in moderate awkward postures were high at all workstations. Neck and wrist excessive awkward postures were observed for most workstations. The average values of the 91st percentile for back flexion and right/left arm elevation were 25°, 62°, and 57°, respectively. The 91st and 9th percentile averages for neck flexion/extension were 35.9° and −4.7°, respectively. An insignificant relationship was found between the percentage of time spent in awkward upper limb posture and musculoskeletal symptoms. The findings provide objective and quantitative data about time exposure, variability, and potential risk factors in the real workplace. Quantitative measurements in the field provide objective data of the body postures and movements of tasks that can be helpful in the musculoskeletal disorders (MSDs) prevention program.
... The most common error detected was placing not fully dried PCB on the conveyor, which will be categorized as defects if the coating is sticky for the next process. Previous studies had shown ergonomic issues can produce poor quality assembled products and defects to customers [13,14]. ...
Lean manufacturing has been one of the techniques to eliminate waste in production to increase productivity. Improper usage of cycle time can extend lead-time of delivery for the production and incur more cost than needed. Determining sufficient cycle time is important to ensure the productivity of the each assembly line is within the delivery time span. Improvement of productivity contributes in maintaining sustainable environment that attracts customer and government supports. In this paper, a case study in a manufacturing assembly line was conducted to identify the operator’s motion waste as non-value added activity. As a result, the cycle time was reduced from 60 seconds to 50 seconds in a multiple engaging production activities besides improving the ergonomic posture of the operators. A double four stages rack was designed to reduce the cycle time by 16.7%, which leads to increment of 1000 units of products per month. The rack was built-in together within the assembly process and reduced movement of operators.
... However, the evaluation process of a manual assembly task should utilize more than one measure to be sufficiently precise for use [9]. According to [10], multiple assessments of assembly ergonomics in sequence of assembly, force exertion, postures prediction and time required to perform an operation have a great influence on the performance of the assembly quality and human safety. Multi-objective functions that evaluate various performance measures of manual assembly can then be based on the number of assembly operations, the time required to perform the task and the difficulty associated; and these functions can be related to the physical proficiency of the assembler. ...
The analysis of manual assembly features and performance indicators is well reported in the literature. Awkward working postures and energy expenditure are known to be the major elements affecting the ergonomic of the manual assembler. However, such investigations are not fully discussed in non-repetitive operations. We therefore conducted a comprehensive ergonomic analysis of the manual assembly process of a SAE Baja racing car at a Mechanical Skills Workshop. Through an experimental set-up to collect data, the observation of the manual assembly operation of a SAE Baja racing car was performed. Purposeful sampling determined the specific elements that were critical to the analysis. The postural disposition of an assembler performing 24 similar work elements was studied. According to REBA, the assembly operations required further investigation and change. Based on the essential assembly-ergonomic components of the study, the energy expenditure of the tasks was derived, and the coefficients of determination R² gave an indication of the level of correlation between the parameters of the manual assembly operation. To complete the study, we give examples of corrective measures that could formalize the working postures of the assembler, thus reducing the risk of physical discomfort and, subsequently helping in sustaining manual assembly operations.
This article focuses on the economics of quality assurance in legal translations. This article first provides an overview of cost-benefit analysis in legal translation and discusses the decision-making process in this economic activity. What follows is a discussion based on the importance of quality assurance in decision-making. Due to globalization, internationalization, and the ever-increasing demand for services or business overseas, legal translation is more important than ever. Without high-quality legal translation, countries cannot communicate due to language differences, and legal translators are essential to perform their duties correctly. Today, legal translation is no longer an option but a necessity. However, legal translation is an almost art profession that requires translators to have language proficiency and good legal knowledge, and we must always find a balance between quality control strategies and related costs. A topic we must pay attention to. Improving productivity and efficiency, conserving our resources, and improving translation quality are all goals to expand and expand language options. To sum up, if we want to lead the evolution of legal translation and predict future trends, we need to do more research, track new technologies, and understand how the processes and economics work so that we can understand subsequent developments in the legal translation market will come.
Aim
With the increasing presence of individuals, particularly women, in the workplace, it becomes imperative to prioritize the well-being of employees. Numerous interventions exist to enhance working conditions, and one such intervention is the incorporation of music. This research aims to investigate the correlation between music exposure and the working memory of female operators employed in a medical infusion set assembly company.
Methods
The study involved the assessment of 81 employees from the assembly unit of a company specializing in the production of infusion sets. The current research is an interventional study, the data of which were collected by the method of interview and cognitive tests (N-back test). The evaluation was conducted under two conditions: with background music and without background music. The research focused on assessing the working memory and productivity (task performance) of the participants.
Results
The mean age of the participants in this study was 37 ± 33.09 years, with a mean work history of 0.2 ± 1.3 years. Furthermore, 56.7% of the participants were married. The results of the study showed that productivity was significantly better in the music-playing mode ( P = 0.005). Furthermore, the results of the N-back test significantly showed an increase in correct answers in the condition of playing music ( P < 0.05).
Conclusions
The integration of background music in the workplace emerges as a beneficial factor, contributing to enhanced working memory and improved performance among female employees.
The issues of intensifying manufacturing processes and increasing the level of its automation are a priority in modern mechanical engineering. The introduction of lean manufacturing technologies and Industry 4.0, ERP will improve the competitiveness of SME enterprises. Despite the high level of process automation in the conditions of SME enterprises, manufacturing operations in which a human participates remains a narrow problem in the process chain. Flexible and quick changes in the production of SME enterprises create tension in the work process for a human, which is spontaneous and depends not only on the physical and emotional state of the worker but also on the process’s information tension. The paper deals with the issues of the accuracy of estimating the time for a manufacturing operation performed by a manufacturing complex, with human participation, which depends on the accuracy and detail of information about the nature of the change in the employee’s working capacity who services the equipment. To improve the accuracy of constructing the characteristics of changes in the employee’s ability to work, the growth factors of the employee’s information tension, reflected in the speed of solving elementary manufacturing employees, were considered. The practical value of the study lies in studying ways to improve the efficiency of manufacturing processes of SME enterprises in the conditions of Industry 4.0 due to the possibility of increasing the level of its automation while reducing the manufacturing process’s information tension, depending on the character’s techniques and equipment.KeywordsIndustry 4.0Manufacturing complexEquipmentFixtureWorking capacityManufacturing methodInformation stress
There are many approaches on how to make digital manikins replicate how real humans perform tasks. The manikin motions can, for instance, be computed by algorithms based on task instructions from the DHM tool user. In this study, we investigate possibilities for improving the task instruction language used in the DHM software tools. The study focuses on identifying opportunities and challenges for how the task instruction language can be improved, and the goal of the study is to establish research questions and to create a research roadmap. The aims of the research questions and associated research and development are: (i) to make it easier to give task instructions; (ii) to reduce the variance in simulations results between different DHM tool users; and (iii) to improve the trustworthiness of the simulation results, related to issues such as manikin behavior and estimated motion times. The potential approaches that have been identified, and will be elaborated and discussed in this paper, with the DHM software tool IPS IMMA as base, are: (i) to enable the DHM tool user to give task instructions on a higher abstraction level than today; (ii) to incorporate functionality to automatically represent likely human behavior; and (iii) to improve the accuracy of time estimation of task performance.KeywordsDigital Human ModellingInstruction LanguageIntelligenceVirtual AssemblySimulation
Passive shoulder exoskeletons are increasingly used as assistive devices to reduce the physical demands on the shoulder region during work-related tasks. This study evaluates the effects of the Exo4Work exoskeleton on musculoskeletal loading during working activities in real-life conditions in the workplace. Inertial measurement units and electromyography were used to analyze the effects of the Exo4Work exoskeleton in 5 workers executing their routine occupational tasks in the workplace. The IMU-based kinematics were then used as input for a musculoskeletal modeling workflow to investigate muscle force distribution. Despite system usability scores comparable to previously investigated exoskeletons, there was no effect of the exoskeleton on musculoskeletal loading. Furthermore, shoulder muscle EMG activity was not consistently reduced in all 5 participants. This is the first study investigating the effect of a passive shoulder exoskeleton on full-body musculoskeletal loading in the workplace using a musculoskeletal modeling approach based on joint kinematics estimated by inertial measurement units. The exoskeleton did not affect musculoskeletal loading in the workplace. These findings contradict the reductions in musculoskeletal loading observed in the laboratory with the Exo4Work shoulder exoskeleton reported by our group.KeywordsPassive shoulder exoskeletonfull-body musculoskeletal modelingin-field evaluationInertial measurement units
Simulation has been widely used as a training tool in multiple industries. Due to the immersive and guided real-life experiences, learners can gain technical and non-technical skills in simulation-based training. However, despite the benefits of simulation-based training, research has shown that knowledge transfer may not be a guarantee. One possible explanation is how learning outcomes are assessed in current training programs using simulations. Therefore, in this report, we conducted a bibliometric analysis to understand the current research landscape related to simulation-based training programs and the learning assessments used in programs both in and outside the manufacturing industry. Based on our findings, more research is needed in simulation-based training in manufacturing and the learning assessment related to these training programs. Future research should focus on expanding the data collection to multiple databases and taking a more qualitative look into the current literature by conducting a systematized literature review.Keywordsbibliometric analysissimulation-based trainingmanufacturinglearning assessment
Fatigue is a loss in cognitive or physical performance due to physiological factors such as insufficient sleep, long work hours, stress, and physical exertion. It adversely affects the human body and can slow reaction times, reduce attention, and limit short-term memory. Hence, there is a need to monitor a person’s state to avoid extreme fatigue conditions that can result in physiological complications. However, tools to understand and assess fatigue are minimal. This paper primarily focuses on building an experimental setup that induces cognitive fatigue (CF) and physical fatigue (PF) through multiple cognitive and physical tasks while simultaneously recording physiological data. First, we built a prototype sensor suit embedded with numerous physiological sensors for easy use during data collection. Second, participants’ self-reported visual analog scores (VAS) are reported after each task to confirm fatigue induction. Finally, an evaluation system is built that utilizes machine learning (ML) models to detect states of CF and PF from sensor data, thus providing an objective measure. Our methods beat state-of-the-art approaches, where Random Forest performs the best in detecting PF with an accuracy of 80.5% while correctly predicting the true PF condition 88% of the time. On the other hand, the long short-term memory (LSTM) recurrent neural network produces the best results in detecting CF in the subjects (with 84.1% accuracy, 0.9 recall).Keywordsfatiguecognitive fatiguephysical fatiguemulti-modal sensorsmachine learning
All the facility layouts are designed to enhance productivity. Though automation plays a huge role, still manual workers are considered essential for achieving the perfection of the product. In that case, any layout that doesn’t consider the ergonomics of the workplace to ensure the worker’s health and safety is deemed to be inconsequential. A balanced layout should consider ergonomic variables such as posture, awkward positions, and workstation dimensions. The enhancement of productivity and efficiency in the workflow process along with significant ergonomic improvements can be achieved through simulation. The results obtained are used to validate the procedure and the support methodology. This gives the link between the plant layout variables and ergonomic variables. Amongst the various simulation software, this report discusses FlexSim in detail focusing on the plant and process layout while the ergonomic variable is addressed through the literature survey.KeywordsWorkflow modelproductivitysimulationergonomicsfacility layout
Operators involved in plant and machine maintenance operations are often exposed to many risks due to hazardous tasks. This is evident especially during the maintenance of offshore wind turbines, which implies that the human workers are in contact with dangerous components with risk of falls, as they must climb the turbine to perform their intervention. Therefore, an ethical approach is necessary to promote a more sustainable industrialization and safe work. Studying new safe solutions is essential to improve job conditions and economic growth. A new handling device is proposed for a telerobotic platform that uses collaborative robots and Immersive Virtual Reality (IVR) to increase safety and efficiency in the maintenance of renewable energy machines as offshore wind turbines. The study aims at achieving the SDG8 objectives of Decent Work and Economic Growth by reducing hazards and risks for operators, as well as the SDG7 objective of Affordable and Clean Energy. Two versions of a maneuvering device for remote maintenance of offshore wind turbines are compared in terms of ergonomics and safety. The tests are carried out with a sample of 13 operators also equipped with tactile devices useful to regulate the application of force by the operator when the contact between the tool and the machine to be maintained occurs.KeywordsSDG8SDG7Haptic deviceCollaborative roboticsTeleoperation
Nowadays, computer-aided inspection (CAI) is used to cope with increasing complexity in part manufacturing and the difficulty of physical access to certain workplaces. Therefore, manufacturing companies adopt automated CAI methods to increase the efficiency of the control quality activities. This study aims to capture the current state of the art of literature related to rigid and non-rigid inspection with a focus on the intelligent factory based on CAI. This investigation is a road map of different methods developed and how precise this kind of inspection can be. This paper presents a systematic literature review in the computer-aided inspection field with an extensive assessment of the included studies. After analyzing the relevant papers and industrial documents in detail, we derive deep insights into the different methods developed to inspect parts based on their physical aspects. This study will contribute to the computer-aided inspection field providing methodologies that will make the human intervention useless at one point. Finally, the digital twins’ model has been proposed for an industrial application based on Industry 4.0.KeywordsGeometric inspectionRigid partsDigital twinsGD&TIndustry 4.0Sustainable inspection
This report provides a brief analysis of a lab chair solution chosen for an industrial case study. It includes supporting documentation of company incentives to increase job satisfaction by means of ergonomic modification. The report provides a bibliometric review. Within this review demonstrations are utilized to highlight the research topic. This is accomplished through targeting source searches in google scholar, Scopus, and Web of Science (WoS). The collected data is then analyzed utilizing software such as VOS viewer, Max QDA, Harzing, and Bibexcel. Data synthesis and review are imperative to support the aforementioned claim. With limited exposure in this manufacturing environment, the credibility of the proposed solution comes from the experience and subsequent data of other researched cases. The literature review provides historical qualitative and quantitative data. Human factors methodologies have been historically utilized over the years and across organizations to resolve workstation inefficiencies. The targeted source search shows a strong pattern of profitability for companies that invests in employee ergonomics and increased job satisfaction. Data analysis concludes a universal solution is required to address height distributions to limit musculoskeletal injury. The ergonomic incorporation then leads to increased job satisfaction, and increased job satisfaction benefits business. Therefore, it is mutually beneficial for a company to invest in the well-being of its employees.KeywordsJob satisfactionHeightTaskChairErgonomicsOperator
Ergonomic conditions that are ignored in all materials, machinery, equipment and working environments in workplaces negatively affect employee activities. Ergonomically examining and designing work processes is a policy that will prevent musculoskeletal disorders (MSD), as well as increase the efficiency of the employee and production. The way to protect physical and mental health starts with analysis. In this study, the MSD risks of the workers in the progressive molding line, where spare parts are produced in the automotive sector, were examined by QEC and BAUA ergonomic analysis methods. In order to reduce the strain on the operator due to the working, an improvement suggestion has been developed and applied. QEC and BAUA risk scores on current workstation are 73.30% and 30, respectively. With the new production design carried out on the line, the work process that poses a risk has been made independent from the employee and this work has been made dependent on the machine in the molding line. Thus, the risk scores has been reduced to 55.11% and 2 points. This result shows that with the accurate analysis and production design, the MSD risks that employees may encounter today and in the future can be greatly reduced. In ındustries, the employee's maintaining the job in the wrong position and every unnecessary activity is a waste. In addition, the cost and profit of the application has been revealed with the economic analysis made for the situation where such activities are improved. It has been shown that ergonomic working environments have the potential to increase the yield, reduce costs and reflect in profit. With the research results, it is thought that the facilities can prevent MSD by applying ergonomic analyzes, the measures to be taken as a result of these analyzes and the ergonomic production design will have a positive effect on productivity, regardless of the extent of the improvement.
This study addresses the relationship between human factors (HF) related quality deficits in manufacturing and work-related musculoskeletal disorder (WMSD) risk factors in production staff. A recent systematic review identified 60 HF-related quality risk factors (QRFs) in manufacturing related to product, process and workstation design stages. We investigate the extent to which these identified QRFs are also WMSD risk factors. Each QRF was examined for its relationship with WMSD using a 0 (no relationship) to 10 (strong relationship) scale rubric. The authors rated each QRF separately and then discussed and adjusted their ratings in a review session. Results showed that average median ratings were the highest for QRFs related to product design (8/10), intermediate for QRFs related to workstation design (7/10) and the lowest for QRFs related to process design (5/10). This emphasises the significant role of HF in system design in reducing both quality deficits and risk of developing WMSDs for manufacturing personnel.
Practitioner summary: This study investigates whether human-related risk factors for product quality are also risk factors for work-related musculoskeletal disorders in manufacturing. Results showed a substantial relationship between quality risk factors and WMSD risk factors. This indicates the significant role of human factors in operations design in improving both system performance and human wellbeing.
In production industries, physical loads have been observed for employees. The purpose
of this study was to evaluate the effects of different takt times on the forces and torques
in body joints during loading. The impact of these loads has been investigated in
automotive industry assembly lines. Especially in assembly lines, expectations from
operators are to do processes in a certain time. So, the operator edits his/her speed and
movements to complete this work in time. During this time, physical forces generated
on the operator also vary accordingly. In this study, it was revealed which values are
affected on the body and how the impact will be occured when working fast and
compared with working slow. An integrated system that includes a motion capture
system as hardware sub-system and a tool for physics-based human simulation as
software sub-system was used for data collection. Comprehensive simulated
biomechanical data allowed us to evaluate joint forces and torques the bottom of torso
(L4), top of torso (T12), left shoulder and upper arm (Lshoulder), right shoulder and
upper arm (Rshoulder). The forces and torques on the body joints which occur on the
operator working at the assembly station was determined as 3 axes. In different
scenarios, data received at a real production station was quantified using motion capture
and simulation tool. Results indicate that when the operator worked in 3 seconds
compared with working 5 seconds, there occurred negative impaction the bottom of
torso (L4), top of torso (T12), left shoulder and upper arm (Lshoulder) joint forces and
torques but there was a reduction in the joint force and torque values on the upper arm
(Rshoulder) which is related to the dominant used hand of the operator. Furthermore,
there are fluctuations and peak values in all joint forces and torques at the initial
intervals of the graphs due to the variation in the speed. The initial acceleration is highly
correlated with the risk of musculoskeletal disorders, physical loads and ergonomic
problems. This case means that considering the loads on the operator, accelerating a
process should be better analyzed to raise the production capacity. This study illustrates
the importance of providing the appropriate processing time for the operator.
Keywords: Physical loads, Motion Capture System, assembly line, real-time
ergonomics evaluation, joint forces and torques
In sectors such as aerospace manufacturing, human errors in the assembly of complex products can negatively impact quality, productivity, and safety. Until now, the analysis of assembly errors has focused more on the immediate human‐system interface and less on broader organizational factors. This article presents a case study‐based analysis of assembly errors in the aeronautical industry using the systemic methods AcciMap and Systems‐Theoretic Accident Model and Processes (STAMP). We seek to provide the company with elements to build a quality improvement strategy that considers human factors and ergonomics from a systemic perspective. The data and information necessary to conduct the analysis came from a project carried out at an aerospace manufacturing facility over a period of 12 months. The team had direct and recurrent access to primary data sources and communication with various stakeholders. A total of 31 influencing factors were identified with AcciMap at different levels within the manufacturing system. STAMP made it possible to model the sociotechnical control structure of the assembly process and identify several control flaws leading to hazards. The analysis shows that systemic methods require a high level of understanding of the manufacturing system and access to relatively high amounts of data and information. Therefore, direct contact with the field and stakeholders is crucial. Training quality specialists on systemic methods could support its use and help to close the gap between theory and practice. Globally, the field of quality in manufacturing could benefit from using systemic methods when deemed necessary.
Musculoskeletal disorders (MSDs), often caused by working in non-ergonomic circumstances, are the most important category of work-related diseases. Different methods exist for examining ergonomics through a variety of postural evaluation techniques (e.g. Rapid Entire Body Assessment (REBA)), which are mostly performed through manual survey-based observations. Consequently, measuring ergonomics of operators is time-consuming and happens only sporadically, often after problems occur. Furthermore, as an ergonomist must assign a score to the performed activity, the ergonomics evaluation is subjective. These problems can be resolved by continuous and automated ergonomic load monitoring methods that directly provide feedback to operators. In order to monitor the operator without interfering the task at hand, a vision-based ergonomics monitoring system is developed. Here, ergonomic features (e.g. joint angles) are estimated based on multiple video streams, which are used to calculate an objective ergonomic score using a standard ergonomics evaluation technique. Although cognitive operator support systems (i.e. digital work instructions) for manual assembly environments are widely used, they do typically not include ergonomics information. The goal of the methodology presented in this work is to a) formulate or update digital work instructions, b) provide the operator feedback on its ergonomic soundness via work instructions and c) generate ergonomic risk level reports in an automated way based on the outcomes of the vision-based ergonomics evaluator. Making the ergonomic guidelines context-aware ensures that interventions occur at the right time. The methodology is integrated in a framework for context-aware work instructions and is validated via a proof of concept, based on an actual industrial case. Results show that context-awareness enhances user acceptance and ergonomics of the operator.
The main purpose of this research is to determine the impact of chair ergonomics, posture, and long-term sitting on employee productivity. Furthermore, the paper addresses the relationship between workplace ergonomics, prolonged and continuous sitting, employee burnout, and employee health. A structured survey was used to evaluate employees in manufacturing and service industries. The obtained data was analyzed with reliability statistics, regression analysis, and correlation analysis. The results are interesting, and contradict the majority of the existing findings in this domain. Even though there are limitations, this current study addresses work environment ergonomics in a concise way, providing significant and unexpected results.KeywordsWorkplace ergonomicsEmployee productivitySedentary jobs
Bangladesh is emerging as the highly potential base for the automobile manufacturing. The geographic location of Bangladesh is suitable for exporting automobile. Our low cost labor and business friendly environment are suitable for automobile industry. our growing population and growing demand of automobile also create an opportunity for automobile industry. Growing demand of South-Asian countries our sea port and low cost labor are main recourse to establish an automobile industry. This could be our first heavy metal industry to strengthen our path to developed economy and Digital Bangladesh. It is most important in term of creating employment opportunities, investment in private sector and acquisition of foreign currencies. It will not only fulfill our automotive need and save foreign currencies but also enrich the middle income mass people lifestyle with fulfilling the need of automobile by decreasing its price with our low cost labor and decreasing import taxes. The project An Automobile Industry is located at Mirsarai Economic Zone, Chittagong could be the image of this newly developed, the most potential industrial hub of the whole country. This is one of the appropriate solutions for future of our automobile scenario and industrial boost of the economy of Bangladesh.
OCCUPATIONAL APPLICATIONS
Worker well-being and overall system performance are important elements in the design of production lines. However, studies of industry practice show that current design tools are unable to consider concurrently both productivity aspects (e.g., line balancing and cycle time) and worker well-being related aspects (e.g., the risk of musculoskeletal disorders). Current practice also fails to account for anthropometric diversity in the workforce and does not use the potential of multi-objective simulation-based optimization techniques. Accordingly, a framework consisting of a workflow and a digital tool was designed to assist in the proactive design of workstations to accommodate worker well-being and productivity. This framework uses state-of-the-art optimization techniques to make it easier and quicker for designers to find successful workplace design solutions. A case study to demonstrate the framework is provided.
The aim of this paper is to identify initial requirements for a proactive and human-centered automotive development process, which considers future effects of global trends and challenges. For this, a qualitative case study is conducted on an industrial project, which focused on the effects of demographic development in a worldwide known and leading German automotive manufacturer. The actual demographic situation and future challenges are analyzed with the use of demography relevant criteria by workshops with experts from the manufacturer. Four topics were identified as crucial in the context of demography for the future (ergonomic workplace design, age-differentiated workplace design, intergenerational knowledge transfer, and personnel development). These topics are further explored by an expert workshop. In a case study, requirements for a human-centered automotive development process are derived from the discussions and results of the expert workshop. The paper concludes with an outlook regarding future actions to identify additional requirements and the development of a more human-centered automotive development process for practical use.
Simulation technologies are widely used in industry as they enable efficient creation, testing, and optimization of the design of products and production systems in virtual worlds, rather than creating, testing, and optimizing prototypes in the physical world. In an industrial production context, simulation of productivity and ergonomics helps companies to find and realize optimized solutions that uphold profitability, output, quality, and worker well-being in their production facilities. However, these two types of simulations are typically carried out using separate software, used by different users, with different objectives. This easily causes silo effects, leading to slow development processes and sub-optimal solutions. This paper reports on research related to the realization of an optimization framework that enables the concurrent optimization of aspects relating to both ergonomics and productivity. The framework is meant to facilitate the inclusion of Ergonomics 4.0 in the Industry 4.0 revolution.
Este artigo tem como objetivo realizar uma revisão bibliométrica na Science Direct para criação de um panorama sobre o tema Projeto Centrado no Ser Humano, com o intuito de identificar os autores, as revistas e as palavras-chave mais significativas, bem como o termo mais recorrente para designação do assunto, para facilitar a busca de artigos. A metodologia utilizada consiste na aplicação das três leis bibliométricas clássicas: Lei do Quadrado Inverso de Lotka, Lei da Dispersão do Conhecimento de Bradford e, Lei da Distribuição e Frequência das Palavras em um Texto de Zipf. Os resultados apontam para o fato do tema não ser constituído como uma linha principal tanto na área do Design quanto nas áreas afins e não apresenta, com base na Science Direct, um autor referência. As revistas que concentram maior repertório de artigos sobre o tema são o International Journal of Industrial Ergonomics e a Applied Ergonomics.AbstractThis article aims to realize a bibliometric review on Science Direct to create a outlook about Human Centred Design in order to identify the most significant authors, journals and key-words as well as the most recurrent denomination about the subject. The method employed consist of application of three classical bibliometric laws: the Inverse Square Law of Lotka; the Bradford’s Law of Scattering and; The frequency law of words in a text of Zipf. The results indicate that the subject is not a main subject of Design and related areas and does not have a main author based on Science Direct. The journals covered with more articles about the subject are the International Journal of Industrial Ergonomics and the Applied Ergonomics.
Work-related musculoskeletal disorders are a major concern globally affecting societies, companies, and individuals. To address this, a new sensor-based system is presented: the Smart Workwear System, aimed at facilitating preventive measures by supporting risk assessments, work design, and work technique training. The system has a module-based platform that enables flexibility of sensor-type utilization, depending on the specific application. A module of the Smart Workwear System that utilizes haptic feedback for work technique training is further presented and evaluated in simulated mail sorting on sixteen novice participants for its potential to reduce adverse arm movements and postures in repetitive manual handling. Upper-arm postures were recorded, using an inertial measurement unit (IMU), perceived pain/discomfort with the Borg CR10-scale, and user experience with a semi-structured interview. This study shows that the use of haptic feedback for work technique training has the potential to significantly reduce the time in adverse upper-arm postures after short periods of training. The haptic feedback was experienced positive and usable by the participants and was effective in supporting learning of how to improve postures and movements. It is concluded that this type of sensorized system, using haptic feedback training, is promising for the future, especially when organizations are introducing newly employed staff, when teaching ergonomics to employees in physically demanding jobs, and when performing ergonomics interventions.
Auch wenn die grundsätzlichen, positiven Effekte von ergonomischen Gestaltungsmaßnahmen selten angezweifelt werden, sind betriebliche Entscheider in der Regel am besten von einer solchen Gestaltungsmaßnahme zu überzeugen, wenn der betriebliche Nutzen für sie aufgezeigt werden kann. Wie aus zahlreichen veröffentlichten Studien hervorgeht, kann dieser Nutzen jedoch sehr vielseitige Ausprägungen haben. Diese Übersichtsarbeit wurde als Erweiterung des Ratgebers „Ergonomische Arbeitsplatzgestaltung: Prinzipien aus Trainings-, Sport- und Arbeitswissenschaft zur Entlastung des Bewegungsapparates“ von der Ergoswiss AG beauftragt. Das Ziel dieser Arbeit ist es, veröffentlichte Studienergebnisse zusammenzustellen, welche die Vorteile und den Nutzen („Benefits“) von ergonomischen Gestaltungsmaßnahmen untersucht haben. Neben der grundsätzlichen Betrachtung von ergonomischen Gestaltungsmaßnahmen zur Entlastung des Bewegungsapparats, wird in dieser Übersichtsarbeit der Fokus auf höhenverstellbare Arbeitstische gesetzt.
Purpose
This paper explores some management concepts and how applying these concepts from business to higher education can be problematic, let alone incompatible, particularly in relation to measuring quality in higher education.
Design/methodology/approach
It provides a conceptual understanding of the literature on quality in the higher education context. It does so by examining the literature on students as customers, customer expectations, customer satisfaction and other management theories that have been applied to higher education.
Findings
It argues that the current bases for perceiving quality such as meeting customer expectations, satisfying the customer, ensuring quality control, meeting standards and assessing the cost associated with poor quality are in disagreement with the principal aims and measures of quality in higher education.
Research limitations/implications
This paper can certainly benefit from many other concepts in business that have been applied in higher education, which it lacks. It only focussed on a number of key and popular ideas in management theory that have been used in higher education more broadly.
Practical implications
Student-focussed quality initiatives can be devoid of the student as customer concept. How programs, subjects and experiences are curated can be solely for the purpose of continuous improvement. Second, universities that choose to treat the student as a customer may find it beneficial to apply a relationship marketing approach to higher education. Lastly, those against the student as customer concept may focus on the long-term impact of quality initiatives such as promoting lifelong learning, building long-term relationships with alumni and employers and those that further promote academic integrity.
Originality/value
Some considerations have been offered. These considerations revisit the basic notions of teaching and learning in higher education. It puts an emphasis on sidestepping the student as customer metaphor, that learning is not expressed in dollar terms, and that the quality of the student experience cannot be measured by student evaluation alone because it is felt much later in life.
The purpose of this paper is to research the concepts of productivity and ergonomics and to analyze the effect/impact of ergonomics on human productivity and moreover on total productivity. Increase in productivity should be one of the primary goals of a business today. Without a high level of productivity, an organization cannot be successful today. Therefore, it is appropriate, that increased attention should be given to productivity improvement. In a comprehensive literature survey more than 50 different techniques of productivity improvement were cataloged. These are classified as a) technology-based, b) employee-based, c) product-based, d) task-based and e) material-based techniques. Ergonomics is a part of the task-based techniques.
Cost-benefit analysis (CBA) can help to justify an investment in ergonomics interventions. A predictive CBA model would allow practitioners to present a cost justification to management during the planning stages, but such a model requires reliable estimates of the benefits of ergonomics interventions.
Through literature reviews and Internet searches, 250 case studies that reported the benefits of ergonomics programs and control measures were collected and summarized.
Commonly reported benefits included reductions in the number of work-related musculoskeletal disorders (WMSDs) or their incidence rate, as well as related lost workdays, restricted workdays, and workers' compensation costs. Additional benefits reported were related to productivity, quality, turnover and absenteeism.
Benefits reported were largely positive, and payback periods for ergonomics interventions were typically less than one year.
The results of this review could be used to develop predictive CBA models for ergonomics programs and individual control measures.
Cost-justifying ergonomics interventions prior to implementation may help to secure management support for proposed changes. Numbers used for the benefits side of a cost-benefit analysis (CBA) need to be based on "real world" data in order to be credible. The data presented in this paper may help in the development of simple cost-benefit models for ergonomics programs and control measures.
Several reasons for the failure of business and government decison-makers to more adequately recognize the benefits of human factors/ergonomics and strongly support and endorse its application are reviewed. In particular, the failure of members of our profession to more consisistently and adequately document and publicize the cost-benefits of their ernonomic applications is noted. To support the notion that good ergonomics is good economics, a variety of actual ergonomic applications, and the documented cost-benefits of each, are described.
A cross-sectional case study was performed in a large company producing electro-mechanical products for industrial application. The purpose was to elucidate conditions and strategies for integrating ergonomics into the product development process thereby preventing ergonomic problems at the time of manufacture of new products. In reality the product development process is not a rational problem solving process and does not proceed in a sequential manner as described in engineering models. Instead it is a complex organizational process involving uncertainties, iterative elements and negotiation between key actors. Design and production engineers have a great influence on ergonomics in manufacturing departments. Ergonomics considerations are partly taken into account by production engineers but not as a part of standard operating procedures. There is a number of differences between design and production engineers regarding information sources in problem solving, communication pattern, perception of ergonomics, motivation and requests to support tools and methods. These differences and the social and organizational context of the development process must be taken into account when considering strategies to the integration of ergonomics. Relevance to industryErgonomics considerations at the stage of product development in industry is a major strategy for prevention of work-related injuries and illnesses among employees at the time of manufacture of new products. This study elucidates some important conditions and possibilities for integrating such considerations during the product development process.
The study is aimed at improving productivity and quality, increasing revenue and reducing rejection cost of the manual component insertion (MCI) lines in a printed circuit assembly (PCA) factory. Subjective assessment (through questionnaire), direct observation method, and archival data were used. Live experiments were conducted on production lines. Eleven problems were identified, i.e., long search for materials from the stores, unproductive manual component counting, obstructions during insertions, component fall-off while the PCA board was traveling on a U-shaped conveyor, etc. Interventions were made to rectify the problems, i.e., to have only one central store to eliminate confusion of the materials’ whereabouts, use weighing scale for component counting, modify the MCI sequence and the bin arrangements to avoid obstructions, and use straight conveyor to reduce handling. As a result, there was a tremendous increase in productivity and yearly revenue (US956,136).
As residential construction moves towards industrialized construction methods, ergonomic exposures of construction workers may increase due to heavier components and changes in construction activities. Ergonomic considerations early in the design stages are expected to have the most impact, provided that designers are aware of ergonomic risks and are willing to incorporate ergonomic principles into designs. To determine current knowledge and opinions regarding ergonomics in the context of one commonly used industrialized construction method (prefabricated wall panels), 12 panel designers completed a questionnaire, and seven of those designers participated in a semi-structured interview. Results showed that panel designers generally have little knowledge about the influence of panel designs on workers’ ergonomic risks. Panel designers were neutral or slightly resistant to incorporating ergonomics into designs, due to perceptions of lack of responsibility and influence over workers’ long-term health. Though the participants acknowledged the necessity of ergonomics in panel design, they were concerned with the possibilities of increased workload, costs, and decreased design flexibility. To advance the incorporation of ergonomics in panel design, panel designers need to recognize the potential ergonomic impact of their panel wall system designs. Current research represents an initial step in creating support tools for use in designing wall panel plans that decrease the risk of work-related injuries and illnesses in construction workers.
A typical or conventional workstation for a repetitive drill press operation was evaluated and subsequently redesigned by incorporating the concepts and principles of work design and ergonomics. The production task comprised of drilling four holes on a prepared steel plate. A methods–time measurement (MTM) analysis was conducted to eliminate unnecessary motions and improve the necessary (work) motions involved in task performance. The specific features of the redesigned workstation were specially designed equipment (jig, fixture, etc.), a suitable adjustable chair, proper work height, a placement of tools/equipment within reach envelope, and a comprehensive operator training method. An experimental investigation was conducted to evaluate and test the redesigned workstation in terms of operator productivity (production quantity and quality output) and satisfaction. The increases in quantity (number of holes drilled) and quality (number of good holes drilled) output were 22 and 50%, respectively, for the redesigned workstation compared to the typical or conventional workstation. The high improvement in quality output (50%) could be attributed to the improved design of the jig and fixture and the comprehensive operator training method, which emphasizes the quality aspect of production output. The improvement in operator satisfaction (scores) were highly significant. This investigation has demonstrated the beneficial effect of a combined work design and ergonomics approach, especially for the redesign of a workstation for a repetitive drill press operation. © 2007 Wiley Periodicals, Inc. Hum Factors Man 17: 395–410, 2007.
The marked improvement in workplace safety levels in the past few decades has resulted in companies experiencing fewer safety accidents than before, thus making it less effective to argue that money spent on workplace safety and on injury prevention will yield much bottom-line benefit. To make a compelling business case for workplace safety investment, one must link safety objectives to other business objectives. The objective of this study is to determine whether workplace safety as a business objective adds value to the business bottom line. This research reviews published case studies to determine if there is a relationship between safety initiatives and increased productivity, quality, and cost efficiencies. Eighteen case studies (17 published by the National Safety Council) were analyzed using the Workplace Safety Intervention Appraisal Instrument. The appraisal scores ranged from 0.55 to 1.27, with an average of 0.91. The case studies were relatively strong in the Evidence Reporting and Data Analysis categories, as compared to the Subject Selection, Observation Quality, and Generalization to Other Populations categories. Following workplace safety initiatives, the studies revealed an average increase of 66% (2%–104%) in productivity, 44% (4%–73%) in quality, 82% (52%–100%) in safety records, and 71% (38%–100%) in cost benefits. In a few reported cases, it took only 8 months to obtain a payback in terms of monetary investment in the safety initiative. Although the studies did display a correlation between safety, productivity, and quality, there is insufficient evidence to categorically state that the improvements in productivity, quality, and cost efficiency were brought about by the introduction of an organization-wide safety culture. Notwithstanding, there is demonstrable evidence to indicate that safety as a business objective can assist an organization in achieving the long-term benefit of operational sustainability, that is, achieve a long-term competitive advantage by balancing business costs against social costs. Further research is required to conclusively prove the exact (possibly quantifiable) impact of safety investment on increased productivity, quality, and cost efficiency. © 2008 Wiley Periodicals, Inc.
The aim of this industrial study was to measure relationships between workstation ergonomics and product quality. Quality on two paced manual assembly lines for disposable cameras was measured by the number of defects per week at each workstation. Two ergonomic variables, the time required for the task and the postural deficiencies, were together able to predict over 50% of the quality variance on each assembly line. This study shows the direct effect of ergonomics variables on quality results. © 2001 John Wiley & Sons, Inc.
For years integration of ergonomics into the planning of new production processes has been an ideal for regulating agencies supported by ergonomic experts. But the ideal appears to be difficult to live up to. A development of tools both by agencies and by groups of researchers has been seen as the strategy to move ergonomics from repair activities towards integration into planning. But the tools are available. An overview of the tools developed and discussed in the last two decades in the Scandinavian countries is presented. It is, therefore, argued that the focus shall be on the broader issues of organizational conditions for giving ergonomics a stronger position in the firm. Ergonomists have to tackle these issues, but it implies a new understanding of their roles, which goes beyond the traditional discussion of expert versus facilitator. The paper is based on an evaluation of a Swedish research program of a new approach to intervention studies on musculoskeletal diseases, on a major Danish research program on integrating ergonomics (working environment) into the planning activities of the enterprises and on discussions with the staff of the Danish mandatory occupational health and safety services on their roles as consultants to firms.Relevance to industryIt is often argued from an economic and ergonomic point of view that ergonomic considerations should be integrated into the planning processes, but it is seldom the case in practice. Tools for establishing this integration are available. Therefore, the organizational preconditions should be addressed. This implies a change of the understanding of the role of the people possessing the ergonomic knowledge in and affiliated to the enterprise from ‘expert’ to ‘organizational activist’.
In many studies, ergonomics has been shown to influence human performance. The aim of this paper was to demonstrate important ergonomics influences on quality in industrial production, from the perspective of interactions between humans, technology, organization, and work environment. A second aim was to elaborate on the implications of these findings for the development of quality management strategies. This paper shows that ergonomics problems in terms of adverse work environmental conditions, inappropriate design of technology, and an unsuitable organization are important causes of quality deficiencies. Problem solving aimed at improving ergonomics, quality, and productivity simultaneously is likely to obtain support from most of the interest parties of the company, and may also enhance participation. Ergonomics has the potential of becoming a driving force for the development of new quality management strategies.
Managers Usually can justify financially supporting a proposed ergonomics project only when it is supported by a sound cost-benefit analysis. The factors to consider and sources of information for calculating the costs and benefits of proposed ergonomic projects are described. Based upon his experience and review of numerous ergonomics projects, the common characteristics of successful ergonomics interventions gleaned by the author Lire described and then illustrated by actual documented cases. (C) 2003 Published by Elsevier Ltd.
This paper describes the concepts behind cost benefit analysis in occupational health and safety and introduces the Productivity Assessment Tool, a method by which an analysis may be performed relatively easily in a service or manufacturing workplace. The advantage of using such analyses is to show the important financial role that safe and efficient workplaces play in the workplace.
By using analytical tools, the effectiveness of an intervention (workplace change) may be estimated prior to its introduction.
This places occupational health and safety on the same financial footing as other proposed workplace changes and thus places occupational health and safety in a strong position to attract scarce resources.
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