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

Calzavara, Martina; Faccio, Maurizio; Persona, Alessandro; Zennaro, Ilenia

doi:10.1007/s00170-020-06438-9

Cited by 17 publications

(5 citation statements)

References 57 publications

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“…Repetitive, improper body postures and movements increase the possibility of MSD (Calzavara et al, 2021). This, leads to material and moral losses for employees, employers and the state (Esen and Fığlalı, 2013).…”

Section: Ergonomic Risk Assessmentmentioning

confidence: 99%

Application of Reba and Karakuri Kaizen Techniques to Reduce Ergonomic Risk Levels in a Workplace

ÖZCAN>

2022

Mühendislik Bilimleri Ve Tasarım Dergisi

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Repetitive works and the works done with inappropriate body postures cause musculoskeletal disorders and workforce losses. Design, technology, and humans must come together in ergonomic conditions. In this study, the ergonomic risk levels that employees in automotive production lines being exposed to were determined by the rapid entire body assessment (REBA) method and by considering anthropometric measurements and ergonomic body postures at a line with high risk level, and a shelf system was designed in accordance with the Karakuri working principle. Through the computer-aided design, the system operation was simulated and solutions for ergonomic risks could be provided before the production. The ergonomic risk level, which was “high” in the current situation, could be reduced with the newly designed mechanism, and an ergonomic workspace could be provided for employees. In the new situation, the ergonomic risk level is “low.” In addition to ergonomic improvements, as the manual transportation works of the employee were eliminated, the cycle time of the line, which was 120 s in the first state, was reduced to 100 s after the use of the Karakuri mechanism and the efficiency of the line increases by 17%.

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Section: Ergonomic Risk Assessmentmentioning

confidence: 99%

Application of Reba and Karakuri Kaizen Techniques to Reduce Ergonomic Risk Levels in a Workplace

ÖZCAN>

2022

Mühendislik Bilimleri Ve Tasarım Dergisi

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“…The energy smoothness index is used to distribute the energetic workload among the different stations of the assembly line, disregarding however personal features of assigned workers, which can influence their physical capabilities. The ergonomic approach based on energy expenditure of workers has then been treated in other works concerning line balancing, such as [36].…”

Section: State Of the Art And Motivations Of The Workmentioning

confidence: 99%

Job rotation and human–robot collaboration for enhancing ergonomics in assembly lines by a genetic algorithm

Mura

Dini

2021

Int J Adv Manuf Technol

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Currently, the largest percentage of the employed workforce in the manufacturing industry is involved in the assembly process, making ergonomics a key factor when dealing with assembly-related problems. During these processes, repetitive tasks and heavy component handling are frequent for workers, who may result overloaded from an energetic point of view, thus affecting several aspects not only relating to the human factor but also to potentially reduced productivity. Different organizational strategies and technological solutions could be adopted to overcome these drawbacks. For these purposes, the present paper proposes a genetic algorithm for solving the typical problem of assembly line balancing, taking into account job rotation and human–robot collaboration for enhancing ergonomics of workers. The objectives of the problem are related to both economic aspects and human factor: (i) the cost for implementing the assembly line is minimized, evaluated on the basis of the number of workers and differentiated by skill levels and on equipment installed on workstations, including collaborative robots, and (ii) the energy load variance among workers is also minimized, so as to smooth their energy expenditure in performing the assigned assembly operations, calculated according to their movements, physiological characteristics, job rotations and degree of collaboration with robots. The paper finally presents and discusses the application of the developed tool to an industrial assembly case.

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“…The cellular manufacturing organization is nowadays widely used in industry. Some authors divide this manufacturing organization according to the movement of the worker into walking worker (WW) organization and fixed worker (FW) organization [1]. The research on WW assembly systems is relatively young with not so many case studies regarding these topics [1].…”

Section: Introductionmentioning

confidence: 99%

“…Some authors divide this manufacturing organization according to the movement of the worker into walking worker (WW) organization and fixed worker (FW) organization [1]. The research on WW assembly systems is relatively young with not so many case studies regarding these topics [1]. According to this, WW is a recent concept that includes models like Working Balance (WB), Toyota Sewing System (TSS), Bucket Brigades (BB), and Rabbit Chase (RC).…”

Section: Introductionmentioning

confidence: 99%

Comparison of lean cellular manufacturing organization models: Multiple case study analysis

Bajrić,

Ferizbegović,

Begić-Pecar

2024

PEN

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Cellular manufacturing represents a production system arrangement in which machines, tools, workers, and devices are grouped to produce a single product or a group of products with similar production requirements. By implementing cellular manufacturing, it is possible to significantly influence the elimination of the seven types of Lean waste: transport, inventory, unnecessary motion, waiting, overproduction, overprocessing, and defects. There are various models of a cellular manufacturing organization, and some of the most widely used and studied include the Toyota Sewing System, Bucket Brigades, Working Balance, and Rabbit Chase. This paper aims to present different types of lean cellular manufacturing organizations. By reviewing the literature, the advantages and disadvantages of individual types of cellular manufacturing will be systematized. In the practical part of the paper, the theoretical assumptions will be confirmed, and the impact and robustness of individual types of cellular manufacturing will be explored in different situations. Simulations were performed in real conditions on real products to demonstrate the efficiency of individual types of cellular manufacturing organizations depending on the duration of technological operations. The goal was also to examine the robustness of individual types of cellular organization in case of the absence of certain operators or insufficiently trained operators. The criteria used to compare different cellular models were productivity, non-conformance, WIP inventory, time to deliver the first correct piece, and flow time. Simulations were performed for the Toyota Sewing System, Bucket Brigade, Working Balance, and Rabbit Chase cellular manufacturing concepts. The simulation results indicate significant differences in the performance of individual concepts, where the difference in some criteria can reach up to 100%.

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

Cited by 17 publications

References 57 publications

Application of Reba and Karakuri Kaizen Techniques to Reduce Ergonomic Risk Levels in a Workplace

Application of Reba and Karakuri Kaizen Techniques to Reduce Ergonomic Risk Levels in a Workplace

Job rotation and human–robot collaboration for enhancing ergonomics in assembly lines by a genetic algorithm

Comparison of lean cellular manufacturing organization models: Multiple case study analysis

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