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Context 1
... path of the carts was changed to eliminate or reduce the transportation wastes. Figures 2 and 3 illustrate the current and improved kitting flows, respectively. In Figure 2, parts are kitted in three areas and are then transported to the assembly line. ...
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Physical Testing
To investigate how well the current model worked, two different types of testing were
conducted. The first was using a scale to measure the difference in the weight of the user while
leaning on the support versus standing straight. The reduction in weight due to leaning on the
support was between 3 and 17%. It is important to note...
Citations
... Ergo-VSM approach was used to implement lean and ergonomic principles in a textile industry and resulted in improvement of operational performance and workers' life quality (Sakthi Nagaraj et al., 2019). Ergonomics and Lean principles were integrated to improve internal transportation in a manufacturing environment by redesigning transportation carts (Aqlan, Lam, Ramakrishnan, & Boldrin, 2014). Integration of Lean and socio technical and ergonomics (SE) factors have also been discussed to overcome the implementation gaps in lean processes (Tortorella, Vergara, & Ferreira, 2017). ...
... From above discussion, integration of lean and ergonomics has been given less attention in extant body of literature (Aqlan et al., 2014). The scenario is similar about integrated implementation of lean and automation (Bilberg & Hadar, 2012;Bortolotti & Romano, 2012). ...
Value addition and performance improvement are important to deal with increasing local and global market competitiveness. Interventions and automation based on Lean and ergonomics principles have strong influence on performance improvement of the production systems. This study focuses on implementation of lean manufacturing and ergonomics principles to improve work environment and performance of the soccer manufacturing production line. Work visualization and value stream mapping (VSM) techniques were employed to identify the opportunities for improvements. Time of value and non-value-added activities is recorded using time study method. Working postures and associated risk factors are evaluated using Rapid Entire Body Assessment (REBA) method. Lean manufacturing principles are employed to minimize wastes and non-value added activities. Similarly, improvements in work environment are made through ergonomics interventions. Various models comprising different levels of lean and ergonomics interventions were evaluated through simulation before actual implementation. The results of the finalized model in terms of decrease in cycle time (8.64 to 7.018 seconds), increase in daily production (20505 to 24176 soccer balls), and improved work environment are evident of performance improvements in all aspects. The integration of lean and ergonomics principles leads to improve the productivity and working environment for workers in soccer ball manufacturing industry.
... The authors found that the highest scores obtained were the result of good interactions between the Lean system, ergonomics and safety. Aqlan et al. [18] integrated the principles of Lean manufacturing and ergonomics in order to redesign and improve the internal transport process of electronic parts in a company. Based on the concepts of Lean philosophy and ergonomics, the transport flow was redesigned. ...
Both the Lean philosophy and occupational safety and health have been widely studied, although this has usually been carried out independently. However, the correlation between Lean and occupational safety and health in the industrial context is still underexplored. Indeed, Lean tools can be applied to ensure the best safety environment for workers in each kind of manufacturing process, and this deserves to be studied. The study described here aims to understand the influence of each of a set of four Lean tools used in an industrial context with a strong manual labor component, seeking to determine the influence of each of these Lean tools on the increase in safety obtained through their application. For this purpose, four Lean tools that are quite commonly applied are selected, taking into account previously presented work that pointed to the positive influence of the application of each of these tools on worker safety: total productive maintenance system, Gemba walk, visual management and Yokoten. This study aims to apply these Lean tools and to analyze their impact on productivity, and then, on the safety of a company selected as a target in order to validate the concept. For this purpose, a new tool is created. In the first instance, the tool analyzes the current state of the productive process and the safety level through the study of the risk levels detected in the plant. In terms of productivity results, a reduction between 7% and 12% in cycle time is achieved in four areas of the plant. The feedback from employees showed increased satisfaction with the processes' simplification. To conclude, a 50% reduction in the number of work accidents per month is observed as a result of the implementation of Lean tools. The influence of the selected Lean tools on increasing both productivity and safety is clear, and our results prove the selection of tools to be largely adequate.
... Improvements in health, job satisfaction and job motivation have been reported as the effects of lean manufacturing through interviews and questionnaires done by workers and the analysis of case studies. As a result, workers have noticed an improvement in working conditions and been able to avoid excessive fatigue and accidental injuries [13,22]. ...
... New design of the wagons is (Poka-Yoke) in Japanese a tool means (Error Proofing) that prevents workers from collecting cards. The Ergo principles are also considered in the new design[111].Arezes and Carvalho, 2014: Ergo/ WS + L: Identify the effects most relevant to the implementation of the "Lean Production System" LPS system from Ergo point of view and summarize some potential problems for Ergo in WS due to the misapplication of the LPS. The effects recognized are highlighted in areas of: work step, force and load, motivation of worker, stress & wellbeing, independence and contribution and safety result. ...
Lean Six Sigma methodologies and Ergonomics principles are the main pillars of this thesis given the importance for continuous improvement in assembly workstations. When looking at the introduction of the Ergonomics that has been integrated with Lean and Six Sigma for improvements, it is necessary to understand why these methodologies belong to each other and how they can be handled in the industrial field.
The combination between lean six sigma and ergonomics are embodied, both of which have the basics of industrial engineering. The aim of this research work seeks towards the integration of the basics tools of lean six sigma and principles of ergonomics to highlight the importance of the combination through the theoretical statement of the background of the case study embodied in three-dimensional modules. This lead to create an integrated methodology focused on Lean for waste to be eliminated, Six Sigma for variance to be reduced and ergonomics that plays an important role in workers’ productivity and safety.
... Therefore, the point successful the lean manufacturing is based on the employee's safety and comfortable to prevent from employee disappears. Smith [39], Vieira et al. [83] and Aqlan, [91] found that from workers interview and questionnaires on the case study analysis of the effect of lean manufacturing on worker safety and health have reported increased health, job satisfaction and job motivation will increase the workers performance and the consequently, can avoid from excessive fatigue and accidental injuries and also worker perceive better working conditions. Increasing the injury will disturbed the lean manufacturing process in the long term, the economic saving from quality, productivity and efficiency improvements pay for the higher cost of employee's compensation claims for medical [92]. ...
The purpose of this paper is to prepare a conceptual framework of hybrid lean and ergonomics for assembly manufacturing process based. The research used PDCA approach as a basis in linking the relationship between lean manufacturing and ergonomics. Comprehensive literature review identify the lean ergonomics issues, best practices, and also the way to improve the ergonomic conditions in the workplace, especially those impacting employees on the assembly process. The findings show that the job design strategies for reducing extreme injuries influence by repetitive tasks. Selections of lean tools and technique, human factors analysis and lean performance measure are the key point on the stages of the PDCA conceptual framework for lean ergonomics in working assembly process. This paper also demonstrates by continuous improvement applied between the elimination of waste and increased productivity and the impacts on the ergonomic conditions to carry out operations and consequently by improving the productivity and well-being of its employees based on implementation of PDCA conceptual frameworks.
... Several researches draw eulogistic praise of lean manufacturing strategies, reporting increased health, job satisfaction and job motivation. The results of such studies show that workers perceive better working conditions and avoid excessive fatigue and accidental injuries after the adoption of lean production principles in their workplaces [1][2][3]. Conversely, a parallel research path stresses the disadvantages of lean manufacturing and the negative effects on employee autonomy, work demands and psychological strain. Recent studies claim that lean principles as Just-in-time (JIT) and work standardization increase work pace and lack of recovery [4]. ...
... Worker interviews and questionnaires and case study analysis of the effects of lean manufacturing on worker safety and health have reported increased health, job satisfaction and job motivation. Consequently, workers perceive better working conditions and avoid excessive fatigue and accidental injuries (Aqlan, Lam, Ramakrishnan, & Boldrin, 2014;Smith, 2003;Vieira et al., 2012). A parallel research path has demonstrated the disadvantages of lean production and the negative effects on employee autonomy, work demands and psychological strain (Bao, Winkel, Mathiassen, & Shahnavaz, 1997;Jackson & Martin, 1996;Leroyer, Kraemer-Heriaud, Marescaux, & Frimat, 2006;Lloyd & James, 2008;Ólafsdóttir & Rafnsson, 1998) . ...
Lean manufacturing is a production method that was established in the wake of the Japanese Toyota Production System and rapidly established in the worldwide manufacturing industry. Lean characteristics combine just-in-time practices, work-in-progress and waste reduction, improvement strategies, defect-free production, and standardization. The primary goal of lean thinking is to improve profits and create value by minimizing waste. This study introduces a novel mathematical model to design lean processes in hybrid assembly lines. The aim was to provide an effective, efficient assembly line design tool that meets the lean principles and ergonomic requirements of safe assembly work. Given the production requirements, product characteristics and assembly tasks, the model defines the assembly process for hybrid assembly lines with both manual workers and automated assembly machines. Each assembly line solution ensures an acceptable risk level of repetitive movements, as required by current law.
In the developed industries, it has been demonstrated that the efficient incorporation of Ergonomics in procedures and facilities reduces expenses associated with disability, additional or overtime hours, health care, premiums or incident fines. The Lean tools are complicated and beneficial but it can cause Ergonomics problems with promising modifications. Human wealth, the most significant component in an organisation, often feels the essence of the issues. The objective of this job was to evaluate current science understanding on the effect of implementing Lean manufacturing tools from the point of perspective of Ergonomics in manufacturing sectors. This study informs, based on the literature reviewed, how the incorporation of the ethics of both Lean tools and Ergonomics from the plan stage of the workplace can carry advantage to the safety of the employees and at the same time to increase the power of efficiency improvements. This article as well aims to precede trends and possibilities in this field for upcoming studies.
In 2015, the UN defined well-being and decent work/economic growth as two of 17 sustainable development objectives. Nevertheless, the extreme pressure for businesses to be competitive in their markets of choice seems to be having a negative effect on workers’ well-being. In the manufacturing sector, the effective inclusion of Ergonomics in processes and installations has been proven to decrease costs related to disability, extra or overtime hours, medical care and premiums or fines for occurrences. The aim of this work was to review the existing scientific knowledge about the impact of adopting LPS (Lean Production Systems—a model used to increase competitiveness by the creation of more value for customers with fewer resources) in manufacturing companies from the point of view of Ergonomics. It reports, based on the literature reviewed, how the integration of both LPS and Ergonomics principles, from the workstation design phase onwards, can bring benefits to the workers’ welfare and simultaneously potentiate improvements in productivity. This paper also intends to present trends and opportunities for future research in this area, including in the Industry 4.0 field. In the authors’ opinion, this paper is a valuable contribution for practitioners, in manufacturing environments, and researchers.
The improvement of the current assembly of the motor and casting components for the Haas UMC-750 5-Axis vertical CNC mill includes the evaluation, development and proposal of a new pair of material handling carts. To meet these deliverables, a student team began by assessing the assembly workstation, defining the problem to be solved, researching ergonomics in material handling equipment and drafting the final design of the improved cart models using SolidWorks. The final design considered the initial improvement request from the client, as well as better ergonomic features to enhance the safety of the operators. It was estimated that the new design can provide Haas Automation with savings in material cost and production of the cart. At the same time, by improving the design, the new carts reduce risk of employee injury by decreasing the use of an overhead crane for assembling the motor components. The SolidWorks models and engineering drawings will be presented to Haas Automation in the hope of a future implementation.
