Skip to main content
SpringerLink
Log in
Book cover

International Conference on Applied Human Factors and Ergonomics

AHFE 2017: Advances in Ergonomics of Manufacturing: Managing the Enterprise of the Future pp 167–178Cite as

The Impact of Ergonomics on the Design of Hybrid Multi-model Production Lines in Lean Manufacturing

  • Conference paper
  • First Online:

Part of the book series: Advances in Intelligent Systems and Computing ((AISC,volume 606))

Abstract

Lean manufacturing is a production method aiming to reduce costs and increase productivity by eliminating waste. Previous studies investigating the variations in the quality of working life due to the implementation of lean manufacturing have shown both negative and positive effects on workers health and perceptions of workplace safety and job satisfaction. This study investigates the impact of ergonomics on the design of manufacturing processes following the principles of lean production. A mathematical model is introduced to address the design of hybrid multi-model production lines with both manual and automatic workstations. The model includes the ergonomic risk assessment ensuring an acceptable exposure of the workers to the risk of developing musculoskeletal disorders in hand intensive tasks. The OCRA Index and the Strain Index job analysis methods are included. The aim is to analyze the variations in the solutions of the model, due to the different ergonomic risk assessment method adopted.

This is a preview of subscription content, log in via an institution.

Chapter
USD   29.95
Price excludes VAT (USA)
  • Available as PDF
  • Read on any device
  • Instant download
  • Own it forever
eBook
USD   169.00
Price excludes VAT (USA)
  • Available as EPUB and PDF
  • Read on any device
  • Instant download
  • Own it forever
Softcover Book
USD   219.99
Price excludes VAT (USA)
  • Compact, lightweight edition
  • Dispatched in 3 to 5 business days
  • Free shipping worldwide - see info

Tax calculation will be finalised at checkout

Purchases are for personal use only

Learn about institutional subscriptions

References

  1. Smith, R.T.: Growing an ergonomics culture in manufacturing. Proc. Inst. Mech. Eng. Part B J. Eng. Manuf. 217, 1027–1030 (2003)

    Article  Google Scholar 

  2. Vieira, L., Balbinotti, G., Varasquin, A., Gontijo, L.: Ergonomics and kaizen as strategies for competitiveness: a theoretical and practical in an automotive industry. Work 41, 1756–1762 (2012)

    Google Scholar 

  3. Aqlan, F., Lam, S., Ramakrishnan, S., Boldrin, W.: Integrating lean and ergonomics to improve internal transportation in a manufacturing environment. In: Conference: Industrial and Systems Engineering Research Conference (ISERC) (2014). https://www.highbeam.com/doc/1P3-3491047341.html

  4. Saurin, T., Ferreira, C.F.: The impacts of lean production on working conditions: a case study of a harvester assembly line in Brazil. Int. J. Ind. Ergon. 39, 403–412 (2009)

    Article  Google Scholar 

  5. Berggren, C., Bjorkman, T., Hollander, E.: Are they unbeatable? Report from a field trip to study transplants, the Japanese owned auto plants in North America (1991)

    Google Scholar 

  6. Brenner, M.D., Fairris, D., Ruser, J.: Flexible work practices and occupational safety and health: exploring the relationship between cumulative trauma disorders and workplace transformation. Ind. Relat.: J. Econ. Soc. 43, 242–266 (2004)

    Article  Google Scholar 

  7. Lloyd, C., James, S.: Too much pressure? Retailer power and occupational health and safety in the food processing industry. Work Employ. Soc. 22, 713–730 (2008)

    Article  Google Scholar 

  8. Koukoulaki, T.: The impact of lean production on musculoskeletal and psychosocial risks: an examination of sociotechnical trends over 20 years. Appl. Ergon. 45, 198–212 (2014)

    Article  Google Scholar 

  9. Yassi, A.: Work-related musculoskeletal disorders. Curr. Opin. Rheumatol. 12, 124–130 (2000)

    Article  Google Scholar 

  10. Dul, J., Neumann, W.P.: Ergonomics contributions to company strategies. Appl. Ergon. 40, 745–752 (2009)

    Article  Google Scholar 

  11. Wygant, R.M., White, B.E., Hunt, D.: Combining ergonomics and work measurement for job analysis. Comput. Ind. Eng. 25, 423–426 (1993)

    Article  Google Scholar 

  12. Resnick, M.L., Zanotti, A.: Using ergonomics to target productivity improvements. Comput. Ind. Eng. 33, 185–188 (1997)

    Article  Google Scholar 

  13. Shikdar, A.A., Sawaqed, N.M.: Ergonomics, and occupational health and safety in the oil industry: a managers’ response. Comput. Ind. Eng. 47, 223–232 (2004)

    Article  Google Scholar 

  14. Dul, J., de Vries, H., Verschoof, S., Eveleens, W., Feilzer, A.: Combining economic and social goals in the design of production systems by using ergonomics standards. Comput. Ind. Eng. 47, 207–222 (2004)

    Article  Google Scholar 

  15. Othman, M., Bhuiyan, N., Gouw, G.J.: Integrating workers’ differences into workforce planning. Comput. Ind. Eng. 63, 1096–1106 (2012)

    Article  Google Scholar 

  16. Xu, Z., Ko, J., Cochran, D., Jung, M.: Design of assembly lines with the concurrent consideration of productivity and upper extremity musculoskeletal disorders using linear models. Comput. Ind. Eng. 62, 431–441 (2012)

    Article  Google Scholar 

  17. De Treville, S., Antonakis, J.: Could lean production job design be intrinsically motivating? Contextual, configurational, and levels-of-analysis issues. J. Oper. Manag. 24, 99–123 (2006)

    Article  Google Scholar 

  18. Kester, J.: A lean look at ergonomics. Ind. Eng. 45, 28–32 (2013)

    Google Scholar 

  19. Yusoff, S., Arezes, P., Costa, N., Arezes, P., Baptista, J.S., Barroso, M.P., Carneiro, P., Costa, N., Melo, R., Miguel, A.S., Perestrelo, G., Cordeiro, P.: The Integration of Lean Manufacturing and Ergonomics Approach in Workplace Design, pp. 579–581. Portuguese Society of Occupational Safety and Hygiene (SPOSHO) (2013)

    Google Scholar 

  20. Adler, P.S., Goldoftas, B., Levine, D.I.: Ergonomics, employee involvement, and the toyota production system: a case study of NUMMI’s 1993 model introduction. Ind. Labor Relat. Rev. 50, 416–437 (1997)

    Article  Google Scholar 

  21. Jackson, P.R., Mullarkey, S.: Lean production and health in garment manufacture. J. Occup. Health Psychol. 5(2), 231–245 (2000)

    Article  Google Scholar 

  22. Conti, R., Angelis, J., Cooper, C., Faragher, B., Gill, C.: The effects of just in time/ lean production on worker job stress. Int. J. Oper. Prod. Manage. 26(9), 1013–1038 (2006)

    Article  Google Scholar 

  23. Sprigg, C.A., Jackson, P.R.: Call centers as lean service environments: job-related strain and the mediating role of work design. J. Occup. Health Psychol. 11, 197–212 (2006)

    Article  Google Scholar 

  24. Colombini, D., Occhipinti, E., Delleman, N., Fallentin, N., Kilbom, A., Grieco, A.: Technical committee on musculoskeletal disorders of international ergonomics association: exposure assessment of upper limb repetitive movements: a consensus document developed by the technical committee on musculoskeletal disorders of international ergonomics association (IEA) endorsed by international commission on occupational health (ICOH). G. Ital. Med. Lav. Ergon. 23, 129–142 (2001)

    Google Scholar 

  25. Jones, T., Kumar, S.: Comparison of ergonomic risk assessments in a repetitive high-risk sawmill occupation: Saw-filer. Int. J. Ind. Ergon. 37, 744–753 (2007)

    Article  Google Scholar 

  26. Chiasson, M., Imbeau, D., Aubry, K., Delisle, A.: Comparing the results of eight methods used to evaluate risk factors associated with musculoskeletal disorders. Int. J. Ind. Ergon. 42, 478–488 (2012)

    Article  Google Scholar 

  27. Roman-Liu, D.: Comparison of concepts in easy-to-use methods for MSD risk assessment. Appl. Ergon. 45, 420–427 (2014)

    Article  Google Scholar 

  28. Paulsen, R., Gallu, T., Gilkey, D., Reiser II, R., Murgia, L., Rosecrance, J.: The inter-rater reliability of strain index and OCRA checklist task assessments in cheese processing. Appl. Ergon. 51, 199–204 (2015)

    Article  Google Scholar 

  29. Occhipinti, E.: OCRA: A concise index for the assessment of exposure to repetitive movements of the upper limbs. Ergonomics 41, 1290–1311 (1998)

    Article  Google Scholar 

  30. Garg, A., Moore, J.S., Kapellusch, J.M.: The revised strain index: an improved upper extremity exposure assessment model. Ergonomics 60(7), 912–922 (2016)

    Article  Google Scholar 

  31. Falck, A., Örtengren, R., Rosenqvist, M.: Assembly failures and action cost in relation to complexity level and assembly ergonomics in manual assembly (Part 2). Int. J. Ind. Ergon. 44, 455–459 (2014)

    Article  Google Scholar 

  32. Bevan, S.: Economic impact of musculoskeletal disorders (MSDs) on work in Europe. Best Pract. Res. Clin. Rheumatol. 29, 356–373 (2015)

    Article  Google Scholar 

  33. ISO 11228-3: System of standards for labor safety. ergonomics. manual handling. Part 3. handling of low loads at high frequency (2007)

    Google Scholar 

Download references

Author information

Authors and Affiliations

  1. Department of Industrial Engineering, University of Bologna, viale del Risorgimento 2, 40136, Bologna, Italy

    Lucia Botti, Cristina Mora, Francesco Piana & Alberto Regattieri

Authors
  1. Lucia Botti
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Cristina Mora
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Francesco Piana
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Alberto Regattieri
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Lucia Botti .

Editor information

Editors and Affiliations

  1. Poznan University of Technology, Poznan, Poland

    Stefan Trzcielinski

Rights and permissions

Reprints and permissions

Copyright information

© 2018 Springer International Publishing AG

About this paper

Cite this paper

Botti, L., Mora, C., Piana, F., Regattieri, A. (2018). The Impact of Ergonomics on the Design of Hybrid Multi-model Production Lines in Lean Manufacturing. In: Trzcielinski, S. (eds) Advances in Ergonomics of Manufacturing: Managing the Enterprise of the Future. AHFE 2017. Advances in Intelligent Systems and Computing, vol 606. Springer, Cham. https://doi.org/10.1007/978-3-319-60474-9_16

Download citation

  • DOI: https://doi.org/10.1007/978-3-319-60474-9_16

  • Published:

  • Publisher Name: Springer, Cham

  • Print ISBN: 978-3-319-60473-2

  • Online ISBN: 978-3-319-60474-9

  • eBook Packages: EngineeringEngineering (R0)

Publish with us

Policies and ethics

Search

Navigation