Fine Tuning of Automated Assembly Machines Using Video Analysis

Human/machine interaction is of still importance in the age of automation. Automated assembling devices are customizable products that need basic settings before installation. Capabilities of operators have to be taken into consideration in this process. This paper presents a procedure based on video recording to determine time data for machine settings. It allows the engineers to forecast the expected capacity of individual workstation and the entire production line. A case study from industry is used to illustrate the application of the system

Virtual reality: A human centered tool for improving Manufacturing

International audienceManufacturing is using Virtual Reality tools to enhance the product life cycle. Their definitions are still in flux and it is necessary to define their connections. Thus, firstly, we will introduce more closely some definitions where we will find that, if the Virtual manufacturing concepts originate from machining operations and evolve in this manufacturing area, there exist a lot of applications in different fields such as casting, forging, sheet metalworking and robotics (mechanisms). From the recent projects in Europe or in USA, we notice that the human perception or the simulation of mannequin is more and more needed in both fields. In this context, we have isolated some applications as ergonomic studies, assembly and maintenance simulation, design or training where the virtual reality tools can be applied. Thus, we find out a family of applications where the virtual reality tools give the engineers the main role in the optimization process. We will illustrate our paper by several examples where virtual reality interfaces are used and combined with optimization tools as multi-agent systems

Digital Technologies to Redesign Automatic Machines with a Human-Centric Approach: Application in Industry

Human factors integration is definitely a transdisciplinary and urgent matter in modern factories. Despite the great surge in factory automation in recent years, human-machine interaction is still a crucial aspect and companies need to take care of the workers' wellbeing and performance to enhance the overall system quality and productivity. Nevertheless, ergonomics is poorly considered during the design of complex industrial systems, such as automatic machinery, especially for the lack of practical methodologies and guidelines to promote human factors from the early stages of design or redesign. To overcome this issue, this work proposes a transdisciplinary approach to redesign automatic machinery in compliance with factory ergonomics, using a combination of digital technologies (e.g., digital human simulation, human physiological data monitoring). The paper defines a structure method and related tools to apply a human-centric approach to industrial cases and their validation of a real case, concerning the redesign of a packaging automatic machine. Results show how the proposed approach is useful to detect possible ergonomic issues at the shop floor, identifying in advance risky situations for the operators during operating or maintenance tasks, and leading to an optimized machine able to enhance the workers’ wellbeing and factory productivity at the same time

A general computer-based methodology for work injury analysis in a production assembly line

Repetitive injuries have been a major obstacle in production assembly lines all over the world. These injuries have greatly reduced the production efficiency of assembly plants and also negatively affected human health. Various attempts have been made by the Canadian government through the Worker’s Compensation Board (WCB) to prevent the occurrences of these injuries because of the associated cost and effects. These attempts failed as the cost of injuries acquired in the workplace continues to increase. For example, in New Zealand alone, the total cost of accidents in 2005, is estimated at $300 million (Accident Compensation Corporation, 2005). In Canada, the number of accepted claims alone amount to 15623 people (Workers Compensation Board of Canada, 2003).A human body can be viewed as a mechanism that is composed of links and joints controlled by a central nervous system and are subject to stress, strain, fatigue and failure as can be observed on a regular industrial robot. But unlike the robot which is designed proactively, these stress and strain factors could be because of certain conditions such as inappropriate work posture, poor assembly line design, excessive workload, and poor work conditions. Often, it is almost uncertain to make a conceptual assessment of the appropriate ergonomic design of a production system before the assembly line is built and put in use. This research will propose a general computer-based methodology for analysis of work injuries given an assembly line where human workers perform repetitive operations. The general methodology integrates sophisticated computer software systems for biomechanics simulation with various manual measurement techniques and methods. The research further proposed a simple and handy synthesis method with which problematic areas of assembly line design, with special reference to human work design can be identified and improved. The proposed methodology for analysis and synthesis is then implemented in a real assembly line to understand the effects of different work activities on the human body. Various software packages and motion tracking techniques will be considered prior to the actual implementation of the final methodology. A rule of thumb table will also be presented as a guideline for the re-design process. The research also proposed a general procedure and specific formula within a specific regional context to calculate the costs of worker injuries in real-life assembly system. This formula thus allows us to obtain the total cost of injuries in a production assembly line, making it possible to optimize the design and operation of the assembly line

Development of Kinectᵀᴿ applications for assembly simulation and ergonomic analysis

Marker-less motion capture technology has been harnessed for several years to track human movements for developing various applications. Recently, with the launch of Microsoft Kinect, researchers have been keenly interested in developing applications using this device. Since Kinect is very inexpensive (only $110 at the time of writing this thesis), it is a low-cost and a promising substitute for the comparatively expensive marker-based motion capture systems. Though it is principally designed for home entertainment, numerous applications can be developed with the capabilities of Kinect. The skeleton data of a human being tracked by a single Kinect device is enough to simulate the human movements, in some cases. However, it is highly desirable to develop a multiple Kinect system to enhance the tracking volume and to address an issue of occlusions. This thesis presents a novel approach for addressing the issue of interference of infrared light patterns while using multiple Kinect devices for human motion capture without lowering the frame rate. This research also presents a software solution to obtain skeleton data from multiple Kinect devices using Kinect for Windows SDK. It also discusses the development of an application involving auto scaling of a human model in digital human modeling software by Siemens Jack and human motion simulation using skeleton tracking data from Kinect to assist the industries with a flexible tool for ergonomic analysis. Further, the capability of this application for obtaining assembly simulations of fastening operations on an aircraft fuselage is also presented. --Abstract, page iii

Automatic assessment of the ergonomic risk for manual manufacturing and assembly activities through optical motion capture technology

Abstract Safeguard the operator health is nowadays a hot topic for most of the companies whose production process relies on manual manufacturing and assembly activities. European legislations, national regulations and international standards force the companies to assess the risk of musculoskeletal disorders of operators while they are performing manual tasks. Furthermore, international corporates typically require their partners to adopt and implement particular indices and procedures to assess the ergonomic risks specific of their industrial sector. The expertise and time required by the ergonomic assessment activity compels the companies to huge financial, human and technological investments. An original Motion Analysis System (MAS) is developed to facilitate the evaluation of most of the ergonomic indices traditionally adopted by manufacturing firms. The MAS exploits a network of marker-less depth cameras to track and record the operator movements and postures during the performed tasks. The big volume of data provided by this motion capture technology is employed by the MAS to automatically and quantitatively assesses the risk of musculoskeletal disorders over the entire task duration and for each body part. The developed hardware/software architecture is tested and validated with a real industrial case study of a car manufacturer which adopts the European Assembly Worksheet (EAWS) to assess the ergonomic risk of its assembly line operators. The results suggest how the MAS is a powerful architecture compared to other motion capture solutions. Indeed, this technology accurately assesses the operator movements and his joint absolute position in the assembly station 3D layout. Finally, the MAS automatically and quantitatively fill out the different EAWS sections, traditionally evaluated through time- and resource-consuming activities