An integrated methodology for manufacturing systems design using manual and computer simulation

Abstract

Traditional approaches to manufacturing systems design utilize a sequential procedure that focuses on production capacity requirements, with human operator task design developed late in the systems design phase. Implementing manufacturing systems in this way is difficult when operations management must design flexible and efficient processes, with an often incomplete understanding of how people can best perform within the system. This study developed an integrated methodology that uses both manual and computer simulations to evaluate system performance and ergonomic issues early in the system design process. Information about operator performance and ergonomics is obtained in the manual simulations, while estimates of operator utilization and system throughput is obtained through computer simulations. An iterative design process is used, with the results of manual and computer simulations informing each other during subsequent simulations. An industrial case study is presented here to demonstrate the effectiveness of this methodology. The results show that the methodology can be used to design manufacturing systems with significant savings in labor cost and improved manufacturing system flexibility.

Participatory ergonomics simulation of hospital work systems: The influence of simulation media on simulation outcome

“…The fullscale mock-ups are referred to as giving a bodily experience (Bligård et al, 2014;Persson et al, 2014) and being flexible to use (Paquet and Lin, 2003;Peavey et al, 2012;Villeneuve et al, 2007). The table-top based models are discussed as providing an overview (Bligård et al, 2014;Ruohomäki, 2003;Savolainen, 1997).…”

“…Existing studies on full-scale mock-ups and table-top based models show little consideration in regards to the form of the simulation outcomes, whether being directly applicable in design or challenges to take into account. Few studies define tangible design criteria (Hignett et al, 2010;Villeneuve et al, 2007;Watkins et al, 2008) and assess conditions (Daniellou et al, 2014;Hallbeck et al, 2010;Paquet and Lin, 2003;Ruohomäki, 2003). However, the development of these design criteria and assessment of the conditions are not analyzed in relation to the media fidelity and affordance.…”

“…No changing of room dimensions and shape, the shoeboxes had only one geometry, representing the future rooms. (Hignett et al, 2010;Steinfeld, 2004) -Work posture (Hallbeck et al, 2010) -Operation task time (Paquet and Lin, 2003) -Usability of tools and products (Paquet and Lin, 2003;Watkins et al, 2008) -Furnishing and equipment (Peavey et al, 2012) -Communication technology (Ruohomäki, 2003) Space -Depths, heights and positions (Bligård et al, 2014;Hignett et al, 2010;Peavey et al, 2012;Steinfeld, 2004;Watkins et al, 2008) -Usability of workstations (Paquet and Lin, 2003) -Physical requirements (Paquet and Lin, 2003) -Room dimensions and layout (Peavey et al, 2012;Villeneuve et al, 2007) -Materials (Peavey et al, 2012) -Interior designs (Persson et al, 2014) -Space sizes and planning (Steinfeld, 2004;Watkins et al, 2008) -Plant layout (Daniellou et al, 2014;Riis, 1996) -Depths and relative heights (Bligård et al, 2014) -Spatial provision required (Ewenstein and Whyte, 2007) Organization -Distraction in work (Peavey et al, 2012) -Cognitive workload (Paquet and Lin, 2003) -Work activities (Ruohomäki, 2003) -Human interaction (Ruohomäki, 2003) -Division of work and production schedule (Forssén-Nyberg and Makamäki, 1998;Ruohomäki, 2003;Savolainen, 1997) -Communication and cooperation (Forssén-Nyberg and Makamäki, 1998;Riis, 1996;…”

“…Within the PE field, a variety of different simulation media are applied, all with the purpose of identifying or assessing ergonomics conditions and problems of the work system to be designed. Physical simulation media such as mock-ups and prototypes are applied for assessing work posture (Sundin et al, 2004), muscular discomfort (Paquet and Lin, 2003), physical layout and spatial conditions (Broberg et al, 2011;Steinfeld, 2004;Watkins et al, 2008). Computer based simulation media such as 3D computer animation and mixed reality have been applied for assessing muscular fatigue (Hallbeck et al, 2010;Perez et al, 2014), repetitive work and critical work sequences (Sundin and Medbo, 2003;Sundin et al, 2004).…”

“…The variation in ergonomics conditions indicates that different media support identification and assessment of different ergonomics conditions, which is a common reflection point in the literature (Hallbeck et al, 2010;Paquet and Lin, 2003;Steinfeld, 2004;Sundin and Medbo, 2003;Watkins et al, 2008). In addition, some studies indicate that the media have certain attributes, but these are not reflected upon in relation to the ergonomics conditions or problems actually possible to identify by applying the media.…”