Variations in cycle-time when using knowledge-based tasks for humans and robots

Operator4.0 was coined in 2016 to create a research arena to understand how the physical, cognitive, and sensorial capabilities of an operator could be enhanced by automation. To create an interaction between operator and robots, there are important factors that needs to be defined. Two important factors are the task and function allocation. Without well-defined tasks it is hard to allocate the tasks between the robot and the human to create resource flexibility. Furthermore, it the tasks are knowledge-based rather than rule-based, the cycle time between operators can differ a lot. Two assumptions are discussed regarding knowledge-based tasks and automation. These are also tested in an experiment. Results show that it is a large variation of the cycle time for both humans (between 1,58 minutes up to 4,40 minutes) and robots (between 1,94 minutes up to 4,49 minutes) when it comes to knowledge-based and machine learning systems

Digitalization as Facilitator of Effective Information Sharing in Production Systems

This thesis aims to formulate strategic approaches to digital transformation, which manufacturing companies can apply to make themselves more effective in disseminating and presenting production-related information to shop-floor operators. Therefore, two approaches are proposed. One focuses on disseminating information in production systems; the other focuses on presenting information to shop-floor operators.First, assessing digital maturity can facilitate the effective dissemination of information in production systems and contribute towards a digital transformation to Industry 4.0. Maturity assessments provide an understanding of current capabilities. This enables the formulation of goals for digital transformations and, subsequently, facilitates the creation of development plans to make disseminating information more effective.Second, applying digital technologies can facilitate new capabilities for presenting information to operators and contribute towards a digital transformation to Operator 4.0. Operators work under varying circumstances, which requires varying types of information as cognitive support. Understanding these situational requirements facilitates the selection and subsequent implementation of suitable digital technologies for presenting information to operators more effectively.Together, these two approaches demonstrate how digitalization can facilitate effective information sharing in production systems and for shop-floor operators

Evaluating Cobots for Final Assembly

AbstractCollaborative robots becomes more and more common in lab environment and soon also in industry. In order to create resource- and volume flexibility, dynamic and smart automation could be seen as an answer. This paper has investigated the collaborative robots UR3 and UR5 for O-ring assembly and final assembly, compared to the current state which is performed manually. The methodology Dynamo++ was used for measurement and analysis in terms of LoA (cognitive and physical), cycle-time and quality. Furthermore, automation strategy, safety and easiness of programming was investigated. Results show that collaborative robots have great potential in the middle product volume area. A lot of time, layout space and money could be saved with these solutions. However, standards and safety has to be investigated further in order to reach its fully potential

Virtual training for assembly tasks: a framework for the analysis of the cognitive impact on operators

The importance of training for operators in industrial contexts is widely highlighted in literature. Virtual Reality (VR) technology is considered an efficient solution for training, since it provides immersive, realistic, and interactive simulations environments where the operator can learn-by-doing, far from the risks of the real field. Its efficacy has been demonstrated by several studies, but a proper assessment of the operator’s cognitive response in terms of stress and cognitive load, during the use of such technology, is still lacking. This paper proposes a comprehensive methodology for the analysis of user’s cognitive states, suitable for each kind of training in the industrial sector and beyond. Preliminary feasibility analysis refers to virtual training for assembly of agricultural vehicles. The proposed protocol analysis allowed understanding the operators’ loads to optimize the VR training application, considering the mental demand during the training, and thus avoiding stress, mental overload, improving the user performance

Exploration of digitalized presentation of information for Operator 4.0: Five industrial cases

In the digital transformation of manufacturing companies towards Industry 4.0, shop-floor operators of the future, Operator 4.0, will require digitalized presentation of information as cognitive support for their work. This paper explores five industrial cases where Information Support Technology have been conceptualized and developed. These cases have exemplified how digitalized presentation of information can be approached with considerations of operators with varying cognitive work situations and production characteristics. Furthermore, these new technical capabilities have increased the level of cognitive automation to support operators’ individual abilities to perform their work in an increasingly more complex production environment. In conclusion, Information Support Technology in the service of Operator 4.0 is intimately linked with digitalization strategies for transformation towards Industry 4.0

Production Innovation and Effective Dissemination of Information for Operator 4.0

The manufacturing industry is becoming increasingly more complex as the paradigm of mass-production moves, via mass-customization, towards personalized production and Industry 4.0. This increased complexity in the production system also makes everyday work for shop-floor operators more complex. To take advantage of this complexity, shop-floor operators need to be properly supported in order to perform their important work. The shop-floor operators in this future complex manufacturing industry, the Operator 4.0, need to be supported with the implementation of new cognitive automation solutions. These automation solutions, together with the innovativeness of new processes and organizations will increase the competitiveness of the manufacturing industry. This paper discusses three different aspects of production innovation in the context of the needs and preferences of information for Operator 4.0. Conclusively, product innovations can be applied in the manufacturing processes, and thus becoming process innovations, but the implementation of such innovations require organizational innovations

A socio-technical approach for assistants in human-robot collaboration in industry 4.0

The introduction of technologies disruptive of Industry 4.0 in the workplace integrated through human cyber-physical systems causes operators to face new challenges. These are reflected in the increased demands presented in the operator's capabilities physical, sensory, and cognitive demands. In this research, cognitive demands are the most interesting. In this perspective, assistants are presented as a possible solution, not as a tool but as a set of functions that amplify human capabilities, such as exoskeletons, collaborative robots for physical capabilities, virtual and augmented reality for sensory capabilities. Perhaps chatbots and softbots for cognitive capabilities, then the need arises to ask ourselves: How can operator assistance systems 4.0 be developed in the context of industrial manufacturing? In which capacities does the operator need more assistance? From the current paradigm of systematization, different approaches are used within the context of the workspace in industry 4.0. Thus, the functional resonance analysis method (FRAM) is used to model the workspace from the sociotechnical system approach, where the relationships between the components are the most important among the functions to be developed by the human-robot team. With the use of simulators for both robots and robotic systems, the behavior of the variability of the human-robot team is analyzed. Furthermore, from the perspective of cognitive systems engineering, the workspace can be studied as a joint cognitive system, where cognition is understood as distributed, in a symbiotic relationship between the human and technological agents. The implementation of a case study as a human-robot collaborative workspace allows evaluating the performance of the human-robot team, the impact on the operator's cognitive abilities, and the level of collaboration achieved in the human-robot team through a set of metrics and proven methods in other areas, such as cognitive systems engineering, human-machine interaction, and ergonomics. We conclude by discussing the findings and outlook regarding future research questions and possible developments.La introducción de tecnologías disruptivas de Industria 4.0 en el lugar de trabajo integradas a través de sistemas ciberfísicos humanos hace que los operadores enfrenten nuevos desafíos. Estos se reflejan en el aumento de las demandas presentadas en las capacidades físicas, sensoriales y cognitivas del operador. En esta investigación, las demandas cognitivas son las más interesantes. En esta perspectiva, los asistentes se presentan como una posible solución, no como una herramienta sino como un conjunto de funciones que amplifican las capacidades humanas, como exoesqueletos, robots colaborativos para capacidades físicas, realidad virtual y aumentada para capacidades sensoriales. Quizás chatbots y softbots para capacidades cognitivas, entonces surge la necesidad de preguntarnos: ¿Cómo se pueden desarrollar los sistemas de asistencia al operador 4.0 en el contexto de la fabricación industrial? ¿En qué capacidades el operador necesita más asistencia? A partir del paradigma actual de sistematización, se utilizan diferentes enfoques dentro del contexto del espacio de trabajo en la industria 4.0. Así, se utiliza el método de análisis de resonancia funcional (FRAM) para modelar el espacio de trabajo desde el enfoque del sistema sociotécnico, donde las relaciones entre los componentes son las más importantes entre las funciones a desarrollar por el equipo humano-robot. Con el uso de simuladores tanto para robots como para sistemas robóticos se analiza el comportamiento de la variabilidad del equipo humano-robot. Además, desde la perspectiva de la ingeniería de sistemas cognitivos, el espacio de trabajo puede ser estudiado como un sistema cognitivo conjunto, donde la cognición se entiende distribuida, en una relación simbiótica entre los agentes humanos y tecnológicos. La implementación de un caso de estudio como un espacio de trabajo colaborativo humano-robot permite evaluar el desempeño del equipo humano-robot, el impacto en las habilidades cognitivas del operador y el nivel de colaboración alcanzado en el equipo humano-robot a través de un conjunto de métricas y métodos probados en otras áreas, como la ingeniería de sistemas cognitivos, la interacción hombre-máquina y la ergonomía. Concluimos discutiendo los hallazgos y las perspectivas con respecto a futuras preguntas de investigación y posibles desarrollos.Postprint (published version

Concepts for Digitalisation of Assembly Instructions for Short Takt Times

Operational complexity for shop-floor operators can be reduced with eective presentation of instructions, which in turn improves product quality. While this has been researched for longer takt times, final assembly with shorter takt times requires new approaches to properly support operators. Hence, this paper aims to present findings regarding concepts for digitalised assembly instructions to support shop-floor operators in a mixed model final assembly with shorter takt times. A bottom-up mixed-methods approach was applied in an iterative development process, resulting in concepts for short takt time instructions. The findings indicate how to cognitively support operators in two situations. First, work tasks are preferably taught beforehand, with educational instructions. Second, operators should be supported with simplified instructions, presenting key elements and deviations in real-time. Conclusively, these concepts will increase the likelihood of the instruction to be used by operators, which enables standardised work and contributes to enhanced product quality

A sociotechnical perspective of the Operator 4.0 factory: A literature review and future directions

In this study, I illustrate the sociotechnical perspective of the Operator 4.0 factory, where advanced Industry 4.0 technologies – such as robots, the internet of things, virtual reality are deployed to collaborate with operators and help them to their activities within manufacturing organisations. There is a lack of studies exploring how Operator 4.0 factory operates through the interplay between technologies and workers. I address this gap by conducting a systematic literature review employing the sociotechnical theory. This theory sees an organisation as a work system, composed of social and technical systems and helps understand how the work system operates. Thus, I portray the novel role of Operator 4.0, the enabling technologies of the Operator 4.0 factory and the challenged to implement them, and the instrumental and workforce benefits. The results show that studies are focused on both systems meaning that operator 4.0 plays a crucial role in this factory in conjunction with Industry 4.0 technologies. Organisations adopting such production systems experience instrumental benefits related to a more efficient production process and better workforce conditions. I conclude by proposing some future research avenues