A Methodology for Incorporating Ergonomics into Manufacturing Systems Design

Abstract

Approaches to manufacturing systems design often utilize a sequential procedure that focuses on the use of new and available technologies to improve production capacity, with the roles of employees in production processes considered much later. This study developed a methodology that integrates both manual and computer simulations to evaluate system performance and identify ergonomic problems early in the system design process. Information about operator performance and potential ergonomic risk factors is obtained through manual simulations, and estimates of operator utilization and system throughput are obtained through computer simulations. An iterative design process is used, with the results of manual and computer simulations informing each other during subsequent simulations. The results of an industrial case study in which the methods were applied to the design of a manufacturing cell demonstrate that the methodology can be used to design manufacturing systems with significant savings in labor cost and improved manufacturing system flexibility.

Get full access to this article

View all access options for this article.

References

Aghazadeh

Chapleski

Hirschfeld

(1998). A hazard analysis system for robotic work cells. Human Factors and Ergonomics in Manufacturing, 8(4), 323–330.

Bernard

(1997). Musculoskeletal disorders and workplace factors: A critical review of epidemiologic evidence for work-related musculoskeletal disorders of the neck, upper extremity, and low back. Cincinnati, OH: DHHS, NIOSH (Pub. No 97–141).

Borg

(1982). Psychophysical bases of perceived exertion. Medicen and Science in Sport and Exercise, 14(5), 377–381.

Borg

(1990). Psychophysical scaling with applications in physical work and perception of exertion. Scandinavian Journal of Work, Environment & Health, 16(Suppl.1), 55–58.

Chaffin

(1999). Development of computerized human static strength simulation model for job design. Human Factors and Ergonomics in Manufacturing, 7(4), 305–322.

Chaffin

Muzaffer

(1991). Three-dimensional biomechanical static strength prediction model sensitivity to postural and anthropometric anaccuracies. HE Transactions, 23(3), 215–227.

Corlett

Bishop

(1976). A technique for assessing postural discomfort. Ergonomics, 19(2), 175–182.

Fadier

Ciccotelli

(1999). How to integrate safety in design: Methods and models. Human Factors and Ergonomics in Manufacturing, 9(4): 367–379.

Hart

Staveland

(1988). Development of NASA-TLX (Task Load Index: Results of experimental and theoretical research. In Hancock

P. A.

Meshkati

, Human Mental Workload. Amsterdam: North-Holland, 139–183.

10.

Kasvi

Vartiainen

Pulkkis

Nieminen

(2000). The role of information support systems in the joint optimization of work systems. Human Factors and Ergonomics in Manufacturing, 10(2), 193–221.

11.

Keyserling

(1986). Postural analysis of the trunk and shoulders in simulated real time. Ergonomics, 29(4), 569–583.

12.

Keyserling

Brouwer

Silverstein

(1993). A checklist for evaluating ergonomic risk factors resulting from awkward postures of the legs, trunk and neck. International Journal of Industrial Ergonomics, 9, 283–301.

13.

Miller

J. S.

(1998). Digital humans in the simulated product life cycle. IIE Solutions, 30(3), 24–28.

14.

Mital

(1995). Role of ergonomics in designing for manufacturability and humans in general in advanced manufacturing technology: Preparing the American workforce for global competition beyond the year 2000, International Journal of Industrial Ergonomics, 15(2), 129–135.

15.

National Academy of Science, NRC Steering Committee for the Workshop on Work-Related Musculoskeletal Injuries (1999). Work-Related Musculoskeletal Disorders. Washington D.C.: National Academy Press.