Impact of limiting the ergonomic risk on the economic and productive efficiency of an assembly line

Considering ergonomics at the design phase can lead to assembly lines that protect and improve workers’ health and well-being. However, this may reduce efficiency and productivity. Evaluating the potential benefits of incorporating ergonomics into line design versus the additional costs associated with the number of extra stations required or increased idle time, as well as exploring other ergonomic design alternatives, is critical for decision-makers. An assembly line balancing problem considering time, space and ergonomics, is used to evaluate the impact of ergonomic considerations. A model for maximising line efficiency is proposed and linearised for solution by the solver CPLEX. The mixed-integer linear model is compared to an alternative linearisation approach in which a decision variable is parameterised and then iteratively solved. An example and a case study are used to observe the competitiveness of both solution methods, where the iterative approach is shown to be superior for real size problems. The results show that ergonomic evaluation in line design leads to safer but less productive lines, which in turn increases the number of workstations and costs. Specifically, limiting ergonomic risk to a moderate level for the engine assembly line examined in this study, means maximum daily drop of 27 engines.