Simulation-based time evaluation of basic manual assembly tasks

Abstract

The paper presents a simple simulation model of the lifting procedure that can be used to predict the total time required for the sequence of basic manual assembly tasks depending on the various parameters of the load and with regard to the workers' health. The aim of the research is to determine the appropriateness of using simulation tool for (re)setting time standards for manual assembly tasks. An avatar in the simulation model performs sequences of tasks with a handling mass of up to 20.5 kg. The individual times obtained from the simulation model were analysed and compared with several time prediction methods and validated in laboratory environment. An analysis of the influence of different load parameters on the total time was also performed. Dependency is mostly linear, so from the practitioner point of view, we can predict with reasonable certainty the total time for any sequence of manual assembly tasks for every size and mass of the box. Based on the results we can confirm that simulation tool JACK is suitable not only for ergonomic analyses but also for setting time standards for the workers. Furthermore, with the simulation tool we analyse the process and get the accurate results in shorter time compared to other mentioned methods.

A New Model for Determining Factors Affecting Human Errors in Manual Assembly Processes Using Fuzzy Delphi and DEMATEL Methods

“…Poor instructions and procedures [42], task complexity [43], time pressure [28], workload [2], repetitive task [35,44], and multitasking [45][46][47][48].…”

“…Moreover, many studies focusing on human error have emphasized tool factors, such as using necessary and appropriate tools [36,39], and task factors, such as instructions and procedures [42], task complexity [43], time pressure [2], workload [2], and multitasking [45][46][47][48]. Human errors have been studied extensively, with many previous studies concentrating on organizational factors such as training [25], a lack of supervision, and avoiding the root cause of the error [39].…”

Quick Workplace Analysis Using Simulation

“…As such, simulations are key to improve and evaluate system performance. The use of simulations in company practice can also bring us many other benefits, such as rationalising the number of workers at workplaces; accelerating material flows by adjusting routes; minimising the time needed to produce products at selected workplaces; detecting waste in production [15,16] or realised ergonomic analyses to improve satisfaction in the workplaces [17,18]. The simulations also allow optimisation of the manufacturing system in the context of a multi-objective optimisation problem [19].…”

Transformer Production Improvement by Lean and MTM-2 Technique

“…Researchers have a team that work for this company and hold a position as transformer line production executives who are able to decide experiments and decisions for this research. The study showed methods for improving production processes by reducing cost, time and waste, instead of increasing budgets by applying industrial engineering tools and Lean manufacturing approach [19]. All operations and procedures of transformer production in the case study firm were analyzed by principles of Lean with the time study measurement of workers by MTM2 technique [20][21] [22].…”