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

Ana Colim, Rita Morgado, Paula Carneiro, Nélson Costa, Carlos Faria, Nuno Sousa, Luís A. Rocha and Pedro Arezes
Additional contact information
Ana Colim: DTx Colab, 4800-058 Guimarães, Portugal
Rita Morgado: School of Engineering, University of Minho, 4800-058 Guimarães, Portugal
Paula Carneiro: ALGORITMI Centre, University of Minho, 4800-058 Guimarães, Portugal
Nélson Costa: ALGORITMI Centre, University of Minho, 4800-058 Guimarães, Portugal
Carlos Faria: DTx Colab, 4800-058 Guimarães, Portugal
Nuno Sousa: ALGORITMI Centre, University of Minho, 4800-058 Guimarães, Portugal
Luís A. Rocha: DTx Colab, 4800-058 Guimarães, Portugal
Pedro Arezes: ALGORITMI Centre, University of Minho, 4800-058 Guimarães, Portugal

Sustainability, 2021, vol. 13, issue 4, 1-21

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.

Keywords: ergonomics and human factors; lean manufacturing; collaborative robotics; productivity; musculoskeletal risk (search for similar items in EconPapers)
JEL-codes: O13 Q Q0 Q2 Q3 Q5 Q56 (search for similar items in EconPapers)
Date: 2021
References: View references in EconPapers View complete reference list from CitEc
Citations: View citations in EconPapers (4)

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Persistent link: https://EconPapers.repec.org/RePEc:gam:jsusta:v:13:y:2021:i:4:p:1931-:d:497527

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