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      Lean Manufacturing and Ergonomics Integration: Defining Productivity and Wellbeing Indicators in a Human–Robot Workstation

      , , , , , , ,
      Sustainability
      MDPI AG

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          Abstract

          Lean Manufacturing (LM), Ergonomics and Human Factors (E&HF), and Human–Robot Collaboration (HRC) are vibrant topics for researchers and companies. Among other emergent technologies, collaborative robotics is an innovative solution to reduce ergonomic concerns and improve manufacturing productivity. However, there is a lack of studies providing empirical evidence about the implementation of these technologies, with little or no consideration for E&HF. This study analyzes an industrial implementation of a collaborative robotic workstation for assembly tasks performed by workers with musculoskeletal complaints through a synergistic integration of E&HF and LM principles. We assessed the workstation before and after the implementation of robotic technology and measured different key performance indicators (e.g., production rate) through a time study and direct observation. We considered 40 postures adopted during the assembly tasks and applied three assessment methods: Rapid Upper Limb Assessment, Revised Strain Index, and Key Indicator Method. Furthermore, we conducted a questionnaire to collect more indicators of workers’ wellbeing. This multi-method approach demonstrated that the hybrid workstation achieved: (i) a reduction of production times; (ii) an improvement of ergonomic conditions; and (iii) an enhancement of workers’ wellbeing. This ergonomic lean study based on human-centered principles proved to be a valid and efficient method to implement and assess collaborative workstations, foreseeing the continuous improvement of the involved processes.

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          Most cited references41

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          Industry 4.0 technologies: Implementation patterns in manufacturing companies

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            Industry 4.0: A survey on technologies, applications and open research issues

            Yang Lu (2017)
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              RULA: a survey method for the investigation of work-related upper limb disorders.

              RULA (rapid upper limb assessment) is a survey method developed for use in ergonomics investigations of workplaces where work-related upper limb disorders are reported. This tool requires no special equipment in providing a quick assessment of the postures of the neck, trunk and upper limbs along with muscle function and the external loads experienced by the body. A coding system is used to generate an action list which indicates the level of intervention required to reduce the risks of injury due to physical loading on the operator. It is of particular assistance in fulfilling the assessment requirements of both the European Community Directive (90/270/EEC) on the minimum safety and health requirements for work with display screen equipment and the UK Guidelines on the prevention of work-related upper limb disorders.
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                Author and article information

                Contributors
                Journal
                SUSTDE
                Sustainability
                Sustainability
                MDPI AG
                2071-1050
                February 2021
                February 11 2021
                : 13
                : 4
                : 1931
                Article
                10.3390/su13041931
                7957b93d-25ba-4f69-91fc-7e4c79bd1413
                © 2021

                https://creativecommons.org/licenses/by/4.0/

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