A simulation model for ergonomic design of industrial processes

Abstract

VORATAS KACHITVICHYANUKUL is an assistant professor in industrial and management engineering at The University of lowa. He holds a BS in chemical engineering from National Taiwan University, an M. Eng.from Asian Institute of Technology, and a PhD in industrial engineering from Purdue University. His current research interests are development of integrated simulation environment, special-purpose simulation language, and random variate generation. He is a member of ACM, TIMS, SCS, and IIE. JAMES R. BUCK is professor and chairman of the department of industrial and management engineering at The University of lowa. He holds BS and MS degrees in civil engineering from the Michigan Technological University and a PhD in industrial engineering from the University of Michigan. Prior to academia, he held positions in materials research, construction, and industrial design. He was on the faculties of the University of Michigan-Dearborn and Purdue University. His current teaching and research interests are in engineering ergonomics and economics where he has published about 75 research papers, book chapters, and technical reports. Dr. Buck has consulted with numerous firms and government agencies. He is a Senior Member of IIE and member of TIMS, HFS, ASEE, and Alpha Pi Mu. CHEE-SENG ONG holds a BS(1976), and MS(1979) in computer sciencefrom Purdue University. Since then he has worked as a system programmer with Boeing Commercial Airplane Company and later as a lecturer with the University of Malaya in Malaysia. Currently, he is a system analyst with Micromatics, a computer system house in Malaysia.ABSTRACT This study examines the feasibility and potential benefits of using simulation to aid designers of large industrial processes. A demonstration of simulations is provided in the basic oxygen furnace shop and subsequent steel-making operations prior to rolling slabs. We explore three design situations: (1) a new processing technology, (2) the removal of bottlenecks in current operations, and (3) sensitivities of processing to equipment failures. Overall shop productivity and the time workloads of crews and individual process operators are examined. Contrasts are made on these criteria between the current mode of operation and the potential design situations stated above through simulation experiments. Results of these simulation experiments provide the basis for economic and ergonomic justification as well as indications for further improvements in the ergonomic facets of design.