A case study at the Nissan Barcelona factory to minimize the ergonomic risk and its standard deviation in a mixed-model assembly line

Valhondo, Joaquín Bautista; Pozo, Rocío Alfaro

doi:10.1007/s13748-018-0153-9

Cited by 11 publications

(7 citation statements)

References 21 publications

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“…A combined/general assessment method is applied in [102][103][104][105][106][107]. Within a singleobjective function, Refs.…”

Section: Assembly Line Balancing Problemmentioning

confidence: 99%

“…Given the number of stations and cycle time, different specifications of the objective function are introduced to minimize the maximum risk, the absolute risk deviations between stations, and the difference between the maximum and minimum risk. Within a multi-objective function, the ergonomic risk is minimized in [102,105] regarding the movements of the upper limbs (assessed according to OCRA), awkward body postures (assessed according to RULA), and lifting/lowering activities (assessed according to the NIOSH-Eq). Next to maximum risk value, Ref.…”

Section: Assembly Line Balancing Problemmentioning

confidence: 99%

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Social Sustainability in Production Planning: A Systematic Literature Review

2022

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Sustainable production includes economic, environmental, and social aspects. However, social sustainability has received less attention, especially compared to the economic aspects. Next to technical and organizational measures, social improvements within supply chains can also be achieved through suitable production planning. Within production planning, production programs are determined, and the assignment of available resources (e.g., employees) is specified. Thus, the utilization and workload of employees are defined. This systematic literature review investigates to what extent such employee-related social aspects are reflected in production planning and discusses whether economic aspects dominate them. For this, a Scopus database search was carried out and 76 identified approaches were analyzed and categorized regarding the occurring employee-related social aspects and their implementation. Thus far, the approaches mainly consider single aspects on single planning levels. A consideration of a broad set of aspects along the entire production planning has rarely been studied. In particular, health and safety aspects are considered on the levels of assembly line balancing and job rotation. However, their impact is primarily determined by the specific settings of the decision-maker. To support decision-makers, only a few studies have investigated the effects based on real application scenarios. Further potential might be an extended modeling of social and economic interdependencies and a consideration of employee-related social aspects in medium- to long-term production planning.

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“…A combined/general assessment method is applied in [102][103][104][105][106][107]. Within a singleobjective function, Refs.…”

Section: Assembly Line Balancing Problemmentioning

confidence: 99%

Section: Assembly Line Balancing Problemmentioning

confidence: 99%

Social Sustainability in Production Planning: A Systematic Literature Review

2022

View full text Add to dashboard Cite

show abstract

“…[47,63] develop an integrated assembly line balancing problem considering the energy expenditure of assembly and components picking, while [12] propose to evaluate the same aspects by using REBA method. On the other side, [64,65] consider ergonomics for both assembly line design and balancing, focusing on single-and mixed-model assembly lines. As it can be seen from the literature review here presented, there are few approaches that consider the impact of materials' exposure and components picking on assembly times and operators' ergonomics.…”

Section: Literature Reviewmentioning

confidence: 99%

Walking worker vs fixed worker assembly considering the impact of components exposure on assembly time and energy expenditure

Calzavara

Faccio

Persona

et al. 2021

Int J Adv Manuf Technol

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Recently, the need for assembly systems of better following the market demand has led to the spread of alternative solutions with respect to the traditional fixed worker strategy. Walking worker systems, where operators move across the line to produce the finished product, are gaining always more interest. In this paper, a comparison between the fixed worker (FW) and the walking worker (WW) assembly strategies is provided, by taking into account their differences both in terms of performed activities during assembly and of material exposure at the assembly workstations. The evaluation is carried out through the proposal of a mathematical model, to understand the impact on assembly time and on operators’ energy expenditure. The behavior of the model is investigated both with a parametric analysis and a real case study. The results show that the FW is the best one when the system is working at its maximum throughput, while the WW strategy turns out to be preferable for the lower values of market demand, both from a time and an energy expenditure perspective.

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“…Carrasquillo et al (2017) conducted a simulation analysis to investigate the effect of conveyor type and product sequence on the ergonomic risks to workers' upper body and lower back exertions and total recovery time. Bautista-Valhondo and Alfaro-Pozo (2018) proposed a greedy randomised adaptive search procedure to jointly minimise the ergonomic risk dispersion and the maximum ergonomic risk level. They compared results obtained using the developed procedure with two mixed-integer linear models by applying them to a real industrial application, an automotive engine assembly line.…”

Section: Mixed-model Assembly Linementioning

confidence: 99%

Including rest allowance in mixed-model assembly lines

Finco

Calzavara

Sgarbossa

et al. 2020

International Journal of Production Research

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Including rest allowance in mixed-model assembly lines Abstract Ergonomics has a significant impact on productivity and human safety in manual assembly lines. For this reason, several studies in recent years have proposed including ergonomics in assembly lines. However, most works are focused on simple assembly lines, while only a few studies exist for mixed-model assembly lines (MMALs). Thus, in this paper, we propose a new methodological approach to include physical fatigue and rest allowance (RA) as ergonomic parameters in MMAL problems. For the balancing problem, we propose a linear mathematical model that minimises the cycle time by including RA. For the sequencing decision, we develop a heuristic approach that assigns workers to workstations according to the workers' age and their related maximum physical capacity. Then, we propose a linear sequencing model that minimises the work-overload by also evaluating RA to assign each worker according to her or his features. Finally, to complete the study, we test the mathematical models in a real case application and provide a detailed discussion of the results to highlight the benefits we can achieve with this approach.

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A case study at the Nissan Barcelona factory to minimize the ergonomic risk and its standard deviation in a mixed-model assembly line

Cited by 11 publications

References 21 publications

Social Sustainability in Production Planning: A Systematic Literature Review

Social Sustainability in Production Planning: A Systematic Literature Review

Walking worker vs fixed worker assembly considering the impact of components exposure on assembly time and energy expenditure

Including rest allowance in mixed-model assembly lines

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