Ergonomic intervention on a packing workstation with robotic aid -case study at a furniture manufacturing industry

OSH related risks and opportunities for industrial human-robot interaction: results from literature and practice

Robotic systems are an integral component of today's work place automation, especially in industrial settings. Due to technological advancements, we see new forms of human-robot interaction emerge which are related to different OSH risks and benefits. We present a multifaceted analysis of risks and opportunities regarding robotic systems in the context of task automation in the industrial sector. This includes the scientific perspective through literature review as well as the workers' expectations in form of use case evaluations. Based on the results, with regards to human-centred workplace design and occupational safety and health (OSH), implications for the practical application are derived and presented. For the literature review a selected subset of papers from a systematic review was extracted. Five systematic reviews and meta-analysis (492 primary studies) focused on the topic of task automation via robotic systems and OSH. These were extracted and categorised into physical, psychosocial and organisational factors based on an OSH-factors framework for advanced robotics developed for the European Agency for Safety and Health at Work (EU-OSHA). To assess the workers' perspective, 27 workers from three European manufacturing companies were asked about their expectations regarding benefits and challenges of robotic systems at their workplace. The answers were translated and categorised in accordance with the framework as well. The statements, both from literature and the survey were then analysed according to the qualitative content analysis, to gain additional insight into the underlying structure and trends in them. As a result, new categories were formed deductively. The analysis showed that the framework is capable to help categorise both findings from literature and worker survey into basic categories with good interrater reliability. Regarding the proposed subcategories however, it failed to reflect the complexity of the workers' expectations. The results of the worker evaluation as well as literature findings both predominantly highlight the psychosocial impact these systems may have on workers. Organisational risks or changes are underrepresented in both groups. Workers' initial expectations lean towards a positive impact.

A Feasibility Study on the Conversion from Manual to Semi-Automatic Material Handling in an Oil and Gas Service Company

In manufacturing companies, manual material handling (MMH) involves lifting, pushing, pulling, carrying, moving, and lowering objects, which can lead to musculoskeletal disorders (MSDs) among workers, resulting in high labor costs due to excessive overtime incurred for manual product preparation. The aim of this study was to show how ergonomic measures were used to reduce the risk of MSDs and to reduce operating costs in the warehouse department of an oil and gas service company. A preliminary study using the Nordic Body Map survey showed that the workers experienced pain in various parts of the body, indicating the presence of MSDs. The researchers then used methods such as the Rapid Upper Limb Assessment (RULA), Rapid Entire Body Assessment (REBA), and National Institute for Occupational Safety and Health (NIOSH) assessments to verify whether the MMH activities had an acceptable level of risk. The results revealed that certain manual material handling (MMH) activities were assessed as low–very high risk, with RULA scores ranging from 3 to 7 and REBA scores ranging from 4 to 11. An immediate solution was to replace the manual process with a semi-automatic process using a vacuum lifter. A feasibility study was conducted using the net present value (NPV), internal rate of return (IRR), and payback period to justify the economic viability of the solution. The analysis indicated that implementing the vacuum lifter not only mitigated the risk of MSDs but also reduced the operating costs, demonstrating its viability and profitability. Overall, this study suggests that implementing a vacuum lifter as an assistive device in the warehouse would be a beneficial investment for both the workers and the company, improving both well-being and finances.

Buyer–Supplier Role in Improving Ergonomics in Garment Supplier Factories: Empirical Evidence from the Garment Industry of Bangladesh

Ergonomics is a key concern of garment suppliers to improve their workers’ well-being and efficiency. However, suppliers’ isolated initiatives are not sufficient to improve ergonomics conditions. Thus, buyers’ cooperation and collaboration with suppliers are necessary to make the ergonomic initiatives successful and sustainable. The purpose of this study is to investigate the impact of buyer-assisted ergonomics intervention on suppliers’ performance and the role of buyers’ assistance and suppliers’ initiatives for improving ergonomics conditions in garment supplier factories. Following a qualitative research approach and multiple embedded case study method, this study intervened in supplier factories and collected qualitative and quantitative data from one Danish buyer and their four key suppliers on ergonomics and the role of buyers and suppliers in improving ergonomics conditions. Collected data were analysed by employing both quantitative and qualitative data analysis techniques. This study demonstrates that buyer-assisted ergonomics intervention on the shop floor can improve ergonomics conditions in garment supplier factories. This study also shows that improving ergonomics in supplier factories need joint efforts of buyers and suppliers. The findings of this study will enrich the literature on ergonomics, sustainability, and buyer–supplier relationships by demonstrating how garment suppliers in developing countries can improve ergonomics to meet the expectations of lead buyers and their workers. This is a unique research attempt to understand ergonomics from a buyer–supplier relationship perspective and its impact on the social sustainability of garment suppliers.

Advanced Applications of Industrial Robotics: New Trends and Possibilities

This review is dedicated to the advanced applications of robotic technologies in the industrial field. Robotic solutions in areas with non-intensive applications are presented, and their implementations are analysed. We also provide an overview of survey publications and technical reports, classified by application criteria, and the development of the structure of existing solutions, and identify recent research gaps. The analysis results reveal the background to the existing obstacles and problems. These issues relate to the areas of psychology, human nature, special artificial intelligence (AI) implementation, and the robot-oriented object design paradigm. Analysis of robot applications shows that the existing emerging applications in robotics face technical and psychological obstacles. The results of this review revealed four directions of required advancement in robotics: development of intelligent companions; improved implementation of AI-based solutions; robot-oriented design of objects; and psychological solutions for robot–human collaboration.

Assessing the effectiveness of an ergonomics intervention program with a participatory approach: ergonomics settlement in an Iranian steel industry

PURPOSE

Work-related musculoskeletal disorders (WMSDs) are common occupational problems affecting the health and productivity of workers worldwide. Ergonomic intervention programs (EIPs) can play an effective role in preventing these disorders in the workplace. Assessing the effectiveness of an EIP is a challenge faced by both industries and researchers. This study was aimed at assessing the effectiveness of an EIP on human resources productivity (HRP), musculoskeletal disorders (MSDs), general health and occupational fatigue in a steel industry.

METHODS

This study was conducted in a steel industry in Isfahan, Iran, between 2018 and 2021. To assess the effectiveness of the EIP with a participatory approach, training and redesign of workstations, the criteria of HRP, MSDs, general health and occupational fatigue were investigated before and after the intervention, using HRP Questionnaire, Nordic musculoskeletal questionnaire (NMQ), 28-item General Health Questionnaire (28-GHQ), Swedish Occupational Fatigue Inventory (SOFI-20) and Occupational Fatigue/Exhaustion Recovery (OFER-15) Questionnaire, as data collection tools, respectively.

RESULTS

The implementation of EIP in the studied industry significantly led to an increase in HRP (p < 0.05). The prevalence of MSDs decreased significantly in most regions of the body after the interventions (p < 0.001). In addition, the program significantly improved general health (p < 0.001) and reduced occupational fatigue among employees (p < 0.001).

CONCLUSIONS

The implementation of EIP was significantly effective in working conditions improvement. Therefore, implementing EIP with participatory approach, workforce training, as well as redesigning of workstations are recommended in industries.

Digitalization of Musculoskeletal Risk Assessment in a Robotic-Assisted Assembly Workstation

The ergonomic assessment of adopted working postures is essential for avoiding musculoskeletal risk factors in manufacturing contexts. Several observational methods based on external analyst observations are available; however, they are relatively subjective and suffer low repeatability. Over the past decade, the digitalization of this assessment has received high research interest. Robotic applications have the potential to lighten workers’ workload and improve working conditions. Therefore, this work presents a musculoskeletal risk assessment before and after robotic implementation in an assembly workstation. We also emphasize the importance of using novel and non-intrusive technologies for musculoskeletal risk assessment. A kinematic study was conducted using inertial motion units (IMU) in a convenience sample of two workers during their normal performance of assembly work cycles. The musculoskeletal risk was estimated according to a semi-automated solution, called the Rapid Upper Limb Assessment (RULA) report. Based on previous musculoskeletal problems reported by the company, the assessment centered on the kinematic analysis of functional wrist movements (flexion/extension, ulnar/radial deviation, and pronation/supination). The results of the RULA report showed a reduction in musculoskeletal risk using robotic-assisted assembly. Regarding the kinematic analysis of the wrist during robotic-assisted tasks, a significant posture improvement of 20–45% was registered (considering the angular deviations relative to the neutral wrist position). The results obtained by direct measurements simultaneously reflect the workload and individual characteristics. The current study highlights the importance of an in-field instrumented assessment of musculoskeletal risk and the limitations of the system applied (e.g., unsuitable for tracking the motion of small joints, such as the fingers).

Physical Ergonomic Improvement and Safe Design of an Assembly Workstation through Collaborative Robotics

One of the key interesting features of collaborative robotic applications is the potential to lighten the worker workload and potentiate better working conditions. Moreover, developing robotics applications that meets ergonomic criteria is not always a straightforward endeavor. We propose a framework to guide the safe design and conceptualization of ergonomic-driven collaborative robotics workstations. A multi-disciplinary approach involving robotics and ergonomics and human factors shaped this methodology that leads future engineers through the digital transformation of a manual assembly (with repetitive and hazardous operations) to a hybrid workstation, focusing on the physical ergonomic improvement. The framework follows four main steps, (i) the characterization of the initial condition, (ii) the risk assessment, (iii) the definition of requirements for a safe design, and (iv) the conceptualization of the hybrid workstation with all the normative implications it entails. We applied this methodology to a case study in an assembly workstation of a furniture manufacturing company. Results show that the methodology adopted sets an adequate foundation to accelerate the design and development of new human-centered collaborative robotic workstations.

The effects of ergonomic intervention on the musculoskeletal complaints and fatigue experienced by workers in the traditional metal casting industry

This research aimed to evaluate the effects of ergonomic intervention on the musculoskeletal complaints and fatigue experienced by workers of the traditional metal casting industry that manually pour molten metal into molds. The workers' physical complaints are typically in the form of musculoskeletal complaints, which include (1) an activity aspect, (2) a physical aspect, and (3) a motivational aspect. The method used in this research was stratified random sampling. The subjects (n = 127) were divided into three groups, namely, the process cement department (PCD) group, the loam department (LD) group, and the black sand department (BSD) group. The evaluation was carried out using questionnaires based on musculoskeletal complaints and fatigue. Meanwhile, an assessment of musculoskeletal complaints and fatigue was conducted one month before the ergonomic intervention, and then during follow-ups at one and eight months after the ergonomic intervention. The results showed that the average reduction in musculoskeletal complaints and fatigue experienced by the workers in the LD group was lower than that of the workers in the PCD and BSD groups at one and eight months after the ergonomic intervention. The positive effects of the ergonomic intervention on musculoskeletal complaints were evident in terms of the back, waist, left and right thighs, right knee, right ankle, and left foot (p < 0.05). The positive effects of the ergonomic intervention on the level of activity-based fatigue were felt in the body and legs, and the feeling of wanting to lie down decreased. The motivational fatigue experienced by the workers manifested as difficulty in thinking, concentrating, and controlling behavior, while the physical fatigue experienced by the workers was in the form of headaches, back pain, excessive thirst, and feeling unwell (p < 0.05). It can be concluded that ergonomic intervention can reduce both musculoskeletal complaints and fatigue, especially by conducting a morning briefing, using ergonomic ladles when pouring molten metal into molds, and consuming nutritious food during break times.