IDEAS home Printed from https://ideas.repec.org/a/gam/jsusta/v13y2021i4p1931-d497527.html
   My bibliography  Save this article

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

Author

Listed:
  • 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)

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.

Suggested Citation

  • Ana Colim & Rita Morgado & Paula Carneiro & Nélson Costa & Carlos Faria & Nuno Sousa & Luís A. Rocha & Pedro Arezes, 2021. "Lean Manufacturing and Ergonomics Integration: Defining Productivity and Wellbeing Indicators in a Human–Robot Workstation," Sustainability, MDPI, vol. 13(4), pages 1-21, February.
  • Handle: RePEc:gam:jsusta:v:13:y:2021:i:4:p:1931-:d:497527
    as

    Download full text from publisher

    File URL: https://www.mdpi.com/2071-1050/13/4/1931/pdf
    Download Restriction: no

    File URL: https://www.mdpi.com/2071-1050/13/4/1931/
    Download Restriction: no
    ---><---

    References listed on IDEAS

    as
    1. Ping-Kuo Chen & Itziar Lujan-Blanco & Jordi Fortuny-Santos & Patxi Ruiz-de-Arbulo-López, 2020. "Lean Manufacturing and Environmental Sustainability: The Effects of Employee Involvement, Stakeholder Pressure and ISO 14001," Sustainability, MDPI, vol. 12(18), pages 1-19, September.
    2. Leonilde Varela & Adriana Araújo & Paulo Ávila & Hélio Castro & Goran Putnik, 2019. "Evaluation of the Relation between Lean Manufacturing, Industry 4.0, and Sustainability," Sustainability, MDPI, vol. 11(5), pages 1-19, March.
    3. Luca Gualtieri & Ilaria Palomba & Fabio Antonio Merati & Erwin Rauch & Renato Vidoni, 2020. "Design of Human-Centered Collaborative Assembly Workstations for the Improvement of Operators’ Physical Ergonomics and Production Efficiency: A Case Study," Sustainability, MDPI, vol. 12(9), pages 1-23, April.
    4. Stefania Bait & Alessandro Di Pietro & Massimiliano M. Schiraldi, 2020. "Waste Reduction in Production Processes through Simulation and VSM," Sustainability, MDPI, vol. 12(8), pages 1-14, April.
    Full references (including those not matched with items on IDEAS)

    Citations

    Citations are extracted by the CitEc Project, subscribe to its RSS feed for this item.
    as


    Cited by:

    1. Wang, Qiuchen & Liu, Hongyi & Ore, Fredrik & Wang, Lihui & Hauge, Jannicke Baalsrud & Meijer, Sebastiaan, 2023. "Multi-actor perspectives on human robotic collaboration implementation in the heavy automotive manufacturing industry - A Swedish case study," Technology in Society, Elsevier, vol. 72(C).
    2. Catherine Maware & David M. Parsley, 2022. "The Challenges of Lean Transformation and Implementation in the Manufacturing Sector," Sustainability, MDPI, vol. 14(10), pages 1-24, May.
    3. Federico Fraboni & Hannah Brendel & Luca Pietrantoni, 2023. "Evaluating Organizational Guidelines for Enhancing Psychological Well-Being, Safety, and Performance in Technology Integration," Sustainability, MDPI, vol. 15(10), pages 1-16, May.
    4. Özköse, Hakan & Güney, Gül, 2023. "The effects of industry 4.0 on productivity: A scientific mapping study," Technology in Society, Elsevier, vol. 75(C).

    Most related items

    These are the items that most often cite the same works as this one and are cited by the same works as this one.
    1. Kleber F. Barcia & Lizzi Garcia-Castro & Jorge Abad-Moran, 2022. "Lean Six Sigma Impact Analysis on Sustainability Using Partial Least Squares Structural Equation Modeling (PLS-SEM): A Literature Review," Sustainability, MDPI, vol. 14(5), pages 1-26, March.
    2. Yilmaz, Aysegul & Dora, Manoj & Hezarkhani, Behzad & Kumar, Maneesh, 2022. "Lean and industry 4.0: Mapping determinants and barriers from a social, environmental, and operational perspective," Technological Forecasting and Social Change, Elsevier, vol. 175(C).
    3. Agnieszka A. Tubis & Katarzyna Grzybowska, 2022. "In Search of Industry 4.0 and Logistics 4.0 in Small-Medium Enterprises—A State of the Art Review," Energies, MDPI, vol. 15(22), pages 1-26, November.
    4. Catherine Maware & David M. Parsley, 2022. "The Challenges of Lean Transformation and Implementation in the Manufacturing Sector," Sustainability, MDPI, vol. 14(10), pages 1-24, May.
    5. Bertha Leticia Treviño-Elizondo & Heriberto García-Reyes & Rodrigo E. Peimbert-García, 2023. "A Maturity Model to Become a Smart Organization Based on Lean and Industry 4.0 Synergy," Sustainability, MDPI, vol. 15(17), pages 1-24, September.
    6. ÄŒreÅ¡nar, Rok & Nedelko, Zlatko, 2019. "Competencies as a Criterion for Assessing the Readiness of Organizations for Industry 4.0 - A Missing Dimension," Proceedings- 11th International Conference on Mangement, Enterprise and Benchmarking (MEB 2019),, Óbuda University, Keleti Faculty of Business and Management.
    7. Emilio Rossi & Erminia Attaianese, 2023. "Research Synergies between Sustainability and Human-Centered Design: A Systematic Literature Review," Sustainability, MDPI, vol. 15(17), pages 1-19, August.
    8. Leonilde Varela & Goran D. Putnik, 2022. "Collaborative and Intelligent Networks and Decision Systems and Services for Supporting Engineering and Production Management," Future Internet, MDPI, vol. 14(11), pages 1-6, November.
    9. Syed Mithun Ali & H. M. Belal & Sanjeeb Roy & Md. Tayabur Rahman & Ahmed Shoyeb Raihan, 2025. "Examining the role of soft dimensions on the implementation of ISO 14000 environmental management systems: a graph-theoretic approach," Annals of Operations Research, Springer, vol. 348(3), pages 2049-2074, May.
    10. Kazancoglu, Yigit & Sezer, Muruvvet Deniz & Ozkan-Ozen, Yesim Deniz & Mangla, Sachin Kumar & Kumar, Ajay, 2021. "Industry 4.0 impacts on responsible environmental and societal management in the family business," Technological Forecasting and Social Change, Elsevier, vol. 173(C).
    11. Hien Nguyen Ngoc & Ganix Lasa & Ion Iriarte, 2022. "Human-centred design in industry 4.0: case study review and opportunities for future research," Journal of Intelligent Manufacturing, Springer, vol. 33(1), pages 35-76, January.
    12. Tian, Li & Wang, Qianyun, 2024. "Improving mineral mining enterprises environmental performance through corporate social responsibility practices in China: Implications for minerals policymaking," Resources Policy, Elsevier, vol. 88(C).
    13. Serhan Alshammari & Mohamed Aichouni & Naim Ben Ali & Omar S. Alshammari & Fatimah Alfaraj & Ahmed Baha Eddine Aichouni, 2025. "Impact of Total Quality Management and Lean Manufacturing on Sustainability Performance: An SEM-ANN Approach in Saudi Food Manufacturing," Sustainability, MDPI, vol. 17(5), pages 1-34, March.
    14. Matteo Ferrazzi & Guilherme Luz Tortorella & Wen Li & Federica Costa & Alberto Portioli-Staudacher, 2025. "From People to Performance: Leveraging Soft Lean Practices for Environmental Sustainability in Large-Scale Production," Sustainability, MDPI, vol. 17(9), pages 1-24, April.
    15. Ewa Stawiarska & Danuta Szwajca & Mirosław Matusek & Radosław Wolniak, 2021. "Diagnosis of the Maturity Level of Implementing Industry 4.0 Solutions in Selected Functional Areas of Management of Automotive Companies in Poland," Sustainability, MDPI, vol. 13(9), pages 1-38, April.
    16. Maryam Afghah & Seyed Mojtaba Sajadi & Seyed Mostafa Razavi & Mohammadreza Taghizadeh‐Yazdi, 2023. "Hard dimensions evaluation in sustainable supply chain management for environmentally adaptive and mitigated adverse eco‐effect environmental policies," Business Strategy and the Environment, Wiley Blackwell, vol. 32(7), pages 5044-5067, November.
    17. Fernando E. García-Muiña & María Sonia Medina-Salgado & Anna Maria Ferrari & Marco Cucchi, 2020. "Sustainability Transition in Industry 4.0 and Smart Manufacturing with the Triple-Layered Business Model Canvas," Sustainability, MDPI, vol. 12(6), pages 1-19, March.
    18. Ali Keshvarparast & Daria Battini & Olga Battaia & Amir Pirayesh, 2024. "Collaborative robots in manufacturing and assembly systems: literature review and future research agenda," Journal of Intelligent Manufacturing, Springer, vol. 35(5), pages 2065-2118, June.
    19. Usama Awan & Robert Sroufe & Muhammad Shahbaz, 2021. "Industry 4.0 and the circular economy: A literature review and recommendations for future research," Business Strategy and the Environment, Wiley Blackwell, vol. 30(4), pages 2038-2060, May.
    20. Paweł Kłobukowski & Jacek Pasieczny, 2020. "Impact of Resources on the Development of Local Entrepreneurship in Industry 4.0," Sustainability, MDPI, vol. 12(24), pages 1-25, December.

    More about this item

    Keywords

    ;
    ;
    ;
    ;
    ;

    Statistics

    Access and download statistics

    Corrections

    All material on this site has been provided by the respective publishers and authors. You can help correct errors and omissions. When requesting a correction, please mention this item's handle: RePEc:gam:jsusta:v:13:y:2021:i:4:p:1931-:d:497527. See general information about how to correct material in RePEc.

    If you have authored this item and are not yet registered with RePEc, we encourage you to do it here. This allows to link your profile to this item. It also allows you to accept potential citations to this item that we are uncertain about.

    If CitEc recognized a bibliographic reference but did not link an item in RePEc to it, you can help with this form .

    If you know of missing items citing this one, you can help us creating those links by adding the relevant references in the same way as above, for each refering item. If you are a registered author of this item, you may also want to check the "citations" tab in your RePEc Author Service profile, as there may be some citations waiting for confirmation.

    For technical questions regarding this item, or to correct its authors, title, abstract, bibliographic or download information, contact: MDPI Indexing Manager (email available below). General contact details of provider: https://www.mdpi.com .

    Please note that corrections may take a couple of weeks to filter through the various RePEc services.

    IDEAS is a RePEc service. RePEc uses bibliographic data supplied by the respective publishers.