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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
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    References listed on IDEAS

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    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.
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    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.

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