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Design of Human-Centered Collaborative Assembly Workstations for the Improvement of Operators’ Physical Ergonomics and Production Efficiency: A Case Study

Author

Listed:
  • Luca Gualtieri

    (Industrial Engineering and Automation (IEA), Faculty of Science and Technology, Free University of Bozen-Bolzano, Piazza Università 5, 39100 Bolzano, Italy)

  • Ilaria Palomba

    (Industrial Engineering and Automation (IEA), Faculty of Science and Technology, Free University of Bozen-Bolzano, Piazza Università 5, 39100 Bolzano, Italy)

  • Fabio Antonio Merati

    (Industrial Engineering and Automation (IEA), Faculty of Science and Technology, Free University of Bozen-Bolzano, Piazza Università 5, 39100 Bolzano, Italy)

  • Erwin Rauch

    (Industrial Engineering and Automation (IEA), Faculty of Science and Technology, Free University of Bozen-Bolzano, Piazza Università 5, 39100 Bolzano, Italy)

  • Renato Vidoni

    (Industrial Engineering and Automation (IEA), Faculty of Science and Technology, Free University of Bozen-Bolzano, Piazza Università 5, 39100 Bolzano, Italy)

Abstract

Industrial collaborative robotics is one of the main enabling technologies of Industry 4.0. Collaborative robots are innovative cyber-physical systems, which allow safe and efficient physical interactions with operators by combining typical machine strengths with inimitable human skills. One of the main uses of collaborative robots will be the support of humans in the most physically stressful activities through a reduction of work-related biomechanical overload, especially in manual assembly activities. The improvement of operators’ occupational work conditions and the development of human-centered and ergonomic production systems is one of the key points of the ongoing fourth industrial revolution. The factory of the future should focus on the implementation of adaptable, reconfigurable, and sustainable production systems, which consider the human as their core and valuable part. Strengthening actual assembly workstations by integrating smart automation solutions for the enhancement of operators’ occupational health and safety will be one of the main goals of the near future. In this paper, the transformation of a manual workstation for wire harness assembly into a collaborative and human-centered one is presented. The purpose of the work is to present a case study research for the design of a collaborative workstation to improve the operators’ physical ergonomics while keeping or increasing the level of productivity. Results demonstrate that the achieved solution provides valuable benefits for the operators’ working conditions as well as for the production performance of the companies. In particular, the biomechanical overload of the worker has been reduced by 12.0% for the right part and by 28% for the left part in terms of manual handling, and by 50% for the left part and by 57% for the right part in terms of working postures. In addition, a reduction of the cycle time of 12.3% has been achieved.

Suggested Citation

  • Luca Gualtieri & Ilaria Palomba & Fabio Antonio Merati & Erwin Rauch & Renato Vidoni, 2020. "Design of Human-Centered Collaborative Assembly Workstations for the Improvement of Operators’ Physical Ergonomics and Production Efficiency: A Case Study," Sustainability, MDPI, vol. 12(9), pages 1-23, April.
    • Handle: RePEc:gam:jsusta:v:12:y:2020:i:9:p:3606-:d:352038
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    References listed on IDEAS

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    1. Karl Widerquist, 2018. "The Bottom Line," Exploring the Basic Income Guarantee, in: A Critical Analysis of Basic Income Experiments for Researchers, Policymakers, and Citizens, chapter 0, pages 93-98, Palgrave Macmillan.
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    Cited by:

    1. Agnieszka A. Tubis & Katarzyna Grzybowska, 2022. "In Search of Industry 4.0 and Logistics 4.0 in Small-Medium Enterprises—A State of the Art Review," Energies, MDPI, vol. 15(22), pages 1-26, November.
    2. Ci-Jyun Liang & Marvin H. Cheng, 2023. "Trends in Robotics Research in Occupational Safety and Health: A Scientometric Analysis and Review," IJERPH, MDPI, vol. 20(10), pages 1-21, May.
    3. Ana Colim & Rita Morgado & Paula Carneiro & Nélson Costa & Carlos Faria & Nuno Sousa & Luís A. Rocha & Pedro Arezes, 2021. "Lean Manufacturing and Ergonomics Integration: Defining Productivity and Wellbeing Indicators in a Human–Robot Workstation," Sustainability, MDPI, vol. 13(4), pages 1-21, February.
    4. Davide Gattamelata & Mario Fargnoli, 2022. "Development of a New Procedure for Evaluating Working Postures: An Application in a Manufacturing Company," IJERPH, MDPI, vol. 19(22), pages 1-20, November.
    5. Fei Chao & Gan Lin & Ling Zheng & Xiang Chang & Chih-Min Lin & Longzhi Yang & Changjing Shang, 2020. "An LSTM Based Generative Adversarial Architecture for Robotic Calligraphy Learning System," Sustainability, MDPI, vol. 12(21), pages 1-11, October.
    6. Emilio Rossi & Erminia Attaianese, 2023. "Research Synergies between Sustainability and Human-Centered Design: A Systematic Literature Review," Sustainability, MDPI, vol. 15(17), pages 1-19, August.
    7. Dominic Loske & Matthias Klumpp & Maria Keil & Thomas Neukirchen, 2021. "Logistics Work, Ergonomics and Social Sustainability: Empirical Musculoskeletal System Strain Assessment in Retail Intralogistics," Logistics, MDPI, vol. 5(4), pages 1-25, December.
    8. Hien Nguyen Ngoc & Ganix Lasa & Ion Iriarte, 2022. "Human-centred design in industry 4.0: case study review and opportunities for future research," Journal of Intelligent Manufacturing, Springer, vol. 33(1), pages 35-76, January.

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