Lean manufacturing e ergonomia na industria metalúrgica: uma abordagem integrada para a melhoria de desempenho

Due to an increasingly competive market, most companies can only survive through continuous improvement, by increasing their productivity and reducing costs. The Lean Production System (SPL) is more and more often used for this purpose.However, the workers' well-being is often neglected, leading to musculoskeletal problems and other occupational diseases. Several authors have identified a gap in the literature regarding the identification of the best practices in the integration of the prevention of musculoskeletal diseases in an SPL. The main objective of this thesis is to clarify the relationship between Ergonomics and LPS and provide the necessary tools for practitioners to implement an ergonomic LPS in their production areas. To achieve this objective, a systematic review was performed and case studies were conducted in four production areas in a metallurgical company using Lean concepts, ergonomic analysis and simulation. From the results found in the literature, which were validated by the four case studies, we can conclude that the integration of Ergonomics during an SPL implementation has the potential to result in gains in productivity and simultaneously improve working conditions. To potentiate these results, several components must be taken into account, namely: the integration of ergonomics in the design of the workstation, the tools for monitoring and evaluation, training and the automation of the manual tasks. Beyond the results obtained and the lessons learned from the case studies, two important tools were developed and validated which were a great support to the implementation of future studies in different areas or sectors: the methodology flowchart and ErgoSafeCI (a tool to evaluate and monitor the LPS implementation while taking into account the ergonomic and safety aspects of a production area). This work offers a valuable contribution for researchers and professionals because it demonstrates how the integration of ergonomics into an SPL increases productivity by providing the necessary tools which make it possible to replicate the procedure in other production areas or sectors.Atualmente, devido ao mercado cada vez mais competitivo, a maioria das empresas só sobrevive através da melhoria contínua, aumentando a produtividade e diminuindo os custos. O Sistema de Produção Lean (SPL) é cada vez mais usado com esse objetivo. No entanto, o bem estar dos trabalhadores é muitas vezes negligenciado, levando a problemas músculoesqueléticos e a outras doenças profissionais. Diversos autores identificam uma falha na literatura quanto à identificação das melhores práticas na integração da prevenção das doenças músculoesqueléticas num SPL. O objetivo principal desta tese é clarificar a relação entre a Ergonomia e um SPL e desenvolver as ferramentas necessárias para ajudar os profissionais na implementação de um SPL ergonómico nas suas áreas produtivas. Para atingir esse objetivo foi realizada uma revisão sistemática à literatura e foram desenvolvidos casos de estudo em quatro áreas produtivas numa empresa metalúrgica onde foram usados vários conceitos Lean, análises ergonómicas e a simulação. Através dos resultados encontrados na literatura e validados nos casos de estudo, concluímos que a integração da ergonomia durante a implementação de um SPL resulta em ganhos de produtividade e simultaneamente melhora as condições de trabalho. Para potenciar estes resultados, diversos fatores devem ser considerados, nomeadamente: a integração da ergonomia no desenho do posto trabalho, nas ferramentas de monitorização e avaliação, na formação e a automatização das tarefas manuais. Para além dos resultados obtidos através dos casos de estudo, e da identificação de algumas “best practices” através das lições aprendidas ao longo deste trabalho, foram ainda desenvolvidas e validadas duas ferramentas importantes no apoio à implementação de futuros estudos em diferentes áreas produtivas e setores: a ErgoSafeCI (ferramenta para avaliar e monitorizar a implementação de um SPL considerando os aspetos ergonómicos e de segurança numa área produtiva) e uma proposta de metodologia geral para abordar a questão da integração das práticas Lean com as práticas de ergonomia. Este trabalho apresenta um contributo, que se espera valioso, para investigadores e profissionais por demonstrar como a integração da ergonomia num SPL potencia a produtividade fornecendo as ferramentas necessárias para a replicação da metodologia proposta noutras áreas produtivas.Programa Doutoral em Engenharia e Gestão Industria

Lean manual assembly 4.0: A systematic review

In a demand context of mass customization, shifting towards the mass personalization of products, assembly operations face the trade-off between highly productive automated systems and flexible manual operators. Novel digital technologies—conceptualized as Industry 4.0—suggest the possibility of simultaneously achieving superior productivity and flexibility. This article aims to address how Industry 4.0 technologies could improve the productivity, flexibility and quality of assembly operations. A systematic literature review was carried out, including 234 peer-reviewed articles from 2010–2020. As a result, the analysis was structured addressing four sets of research questions regarding (1) assembly for mass customization; (2) Industry 4.0 and performance evaluation; (3) Lean production as a starting point for smart factories, and (4) the implications of Industry 4.0 for people in assembly operations. It was found that mass customization brings great complexity that needs to be addressed at different levels from a holistic point of view; that Industry 4.0 offers powerful tools to achieve superior productivity and flexibility in assembly; that Lean is a great starting point for implementing such changes; and that people need to be considered central to Assembly 4.0. Developing methodologies for implementing Industry 4.0 to achieve specific business goals remains an open research topic

Application of a mathematical model for ergonomics in lean manufacturing

The data presented in this article are related to the research article \u201cIntegrating ergonomics and lean manufacturing principles in a hybrid assembly line\u201d (Botti et al., 2017) [1]. The results refer to the application of the mathematical model for the design of lean processes in hybrid assembly lines, meeting both the lean principles and the ergonomic requirements for safe assembly work. Data show that the success of a lean strategy is possible when ergonomics of workers is a parameter of the assembly process design

Lean manufacturing and ergonomics integration: defining productivity and wellbeing indicators in a human–robot workstation

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.This work has been supported by NORTE-06-3559-FSE-000018; integrated in the invitation NORTE-59-2018-41, aiming at the Hiring of Highly Qualified Human Resources, co-financed by the Regional Operational Programme of the North 2020, thematic area of Competitiveness and Employment, through the European Social Fund (ESF). This work has been also supported by FCT—Fundação para a Ciência e Tecnologia within the R&D Units Project Scope: UIDB/00319/2020

ErgoVSM: a new tool that integrates ergonomics and productivity

Purpose: Identifying possible ergonomic risks generated by the implementation of Lean Manufacturing in organizations. Shows a need to integrate ergonomics and productivity indicators in process analysis, thus giving place to the ErgoVSM methodology, which is VSM (Value Stream Mapping) complemented with ergonomic analysis. Design/methodology/approach: This literature review aims to refer to the methodology and instruments used for its application, as well as the benefits obtained and the challenges that arise when applying it. Findings: This article presents a review of 26 publications regarding the ErgoVSM methodology. The ErgoVSM is mainly based on the VSM methodology developed by Rother & Shook that is most applied in the healthcare sector with ergonomic analysis instruments that focus on the physical and psychosocial factors of the workers. Originality/value: The review revealed that when using ErgoVSM, processes can be improved from the ergonomic perspective without negatively affecting productivity. Even though ErgoVSM requires more time for application compared to VSM, the value of the ergonomic data for decision making in process changes justifies the extra timePeer Reviewe

Ergonomics Contributions to Company Strategies

Managers usually associate ergonomics with occupational health and safety and related legislation, not with business performance. In many companies, these decision makers seem not to be positively motivated to apply ergonomics for reasons of improving health and safety. In order to strengthen the position of ergonomics and ergonomists in the business and management world, we discuss company strategies and business goals to which ergonomics could contribute. Conceptual models are presented and examples are given to illustrate: 1) the present situation in which ergonomics is not part of regular planning and control cycles in organizations to ensure business performance, and 2) the desired situation in which ergonomics is an integrated part of strategy formulation and implementation. In order to realize the desired situation, considerable changes must take place within the ergonomics research, education and practice community by moving from a health ergonomics paradigm to a business ergonomics paradigm, without losing the health and safety goals.corporate strategy;paradigm shift;system performance

Integration of QRM and ergonomics in the design of a framework in identification complaints among automotive assembly line workers

The assembly line is the most critical area of automotive manufacturing. The smoothness of the production process depends on the situation and conditions of the environment and its workers. The assembly process is done manually by using humans to install all the related components in the production line. Complaints felt by workers during the manufacturing process can hinder the smooth running of production in meeting capacity, thus affecting the company's performance. Therefore, the purpose of this study is to design a framework for identifying workers' complaints by using a combination of Quick Response Manufacturing (QRM) and ergonomics. This framework is expected to identify grievances felt by workers from all aspects of the assembly environment that could potentially impact employment grievances. Framework design is created using the main concept of QRM which consists of time is money, tailoring your dynamics, focusing on the target market segment and thinking gold. Each of these concepts contains ergonomic elements such as workload variables and complaints of musculoskeletal disorders related to production schedules, production time, overtime, facility layout and equipment used. It is hoped that this framework can achieve the desired goal of minimizing work risk in optimizing the production process of the assembly line

Analysis, Design, and Implementation of a training center for variable-speed drive assembly production : Case ABB Oy

In manufacturing constant developments in production, processes, and layouts are required to respond towards increased production volume, quality, and customer requirements while meeting production targets and objectives. The case company of this thesis is ABB Ltd Drives Manufacturing Unit, which specializes in variable-speed drive production. ABB has recognized the need for re-designing a new and effective training center that supports One-piece flow assembly production since the old model is based on a cell production method. The training center is used for the training and integration of the company's new and experienced assemblers. The aim of the research is to analyze the current training concept, design a new technical solution, and create a detailed implementation plan. Thus, the following research questions were developed: RQ1: How to develop and re-design a training center that supports the assembler for One-piece flow method production of variable-speed drives? RQ2: How to design and create the best possible layout and solution to guarantee safety, flexibility, ergonomics, clear flow, and the maximum utilization of space? RQ3: How to implement a training center that does not disrupt the main production lines and makes that way operations more efficient? To achieve the objectives, the waste, bottlenecks, and issues of the current design were first identified by observing the training process and organizing focus groups and workshops with the production line and logistics (customer), and with the project team. Work-time studies were also conducted to solve the flow, outputs, cycle time, and waste time of the current process. These data collection methods aided in identifying potential improvement opportunities for the new design. The layout design process was committed by utilizing Lean principles and the Systematic layout planning procedure. AutoCAD was used to create and map various layout structures, options, and alternatives. The design process required the tendering of two layout location options, which were solved using the quantitative multiple attribute decision-making method, Weighted decision matrix (WDM), with voting based on the scoring of various criteria and features. The result was a Flexible 6-phase U-model one-piece flow training center that allows assemblers to be trained in both one-piece flow and cell production methods. The new design's scope of work was delivered to the supplier, numerous negotiations were held to achieve the best final solution, and the new training center was ordered. In the end, a detailed implementation plan with an estimated schedule was created and a future action list was established. The new design fulfils the objectives and eliminates all issues, waste, and bottlenecks while also ensuring safety, ergonomics, flexibility, a clear flow, and a high-quality training process. With the new design, the efficiency, quality, and output of training and production operations will improve.Teollisuuden alalla tuotantojärjestelmiä, prosesseja ja layouteja on jatkuvasti kehitettävä sekä modifioitava reagoidakseen kasvaneisiin tuotantomääriin sekä laatu- ja asiakasvaatimuksiin ja saavuttaakseen asetetut tuotantotavoitteet ja päämäärät. Tämän opinnäytetyön toimeksiantaja on ABB Oy Drives Manufacturing -yksikkö, joka on erikoistunut taajuusmuuttajatuotantoon. Toimeksiantaja on tunnistanut tarpeen uuden ja tehokkaamman koulutuslinjan suunnitteluun One-piece flow malliseen taajuusmuuttajien kokoonpanotuotantoon, sillä vanha tuotantomalli perustuu solutuotantomenetelmään. Koulutuslinjaa käytetään niin uusien kuten jo talossa olevien vanhojen kokoonpanoasentajien koulutukseen ja integrointiin. Tutkimuksen tavoitteena on analysoida nykyinen koulutuskonsepti, suunnitella uusi tekninen ratkaisu ja laatia yksityiskohtainen implementointisuunnitelma. Tavoitteiden saavuttamista varten on kehitetty seuraavat kolme tutkimuskysymystä: RQ1: Kuinka kehittää ja suunnitella koulutuslinja, joka tukee asentajia One-piece flow malliseen kokoonpanotuotantoon? RQ2: Miten suunnitella ja luoda paras mahdollinen layout ja ratkaisu, joka takaa turvallisuuden, joustavuuden, ergonomian, selkeän virtauksen ja maksimaalisen tilankäytön? RQ3: Kuinka implementoida koulutuslinja, joka ei häiritse päätuotantolinjoja ja tehostaa siten operaatioiden tehokkuutta? Saavuttaakseen tavoitteet, nykyisen koulutuskonseptin aiheuttamat pullonkaulat, ongelmat ja hukka tunnistettiin ensin havainnoimalla koulutusprosessia ja järjestämällä haastatteluja sekä työpajoja tuotantolinjan ja logistiikan (asiakkaan) sekä projektiryhmän kanssa. Nykyisen prosessin virtauksen, ulostulon, tahti -ja hukka-ajan selvittämiseksi suoritettiin myös työaikatutkimuksia. Nämä tiedonkeruumenetelmät auttoivat kehitysmahdollisuuksien tunnistamisessa uutta ratkaisua varten. Layout suunnitteluprosessi toteutettiin Lean-periaatteita ja systemaattista layout suunnittelua käyttäen. AutoCAD layout suunnittelusovellusta käytettiin erilaisien asettelurakenteiden ja vaihtoehtojen luomiseen sekä kartoittamiseen. Suunnitteluprosessi edellytti kahden layout-sijaintivaihtoehdon kilpailuttamista. Lopputulos ratkaistiin äänestämällä kvantitatiivisen päätöksentekomatriisin (WDM) avulla, joka perustui eri kriteerien ja ominaisuuksien pisteytykseen. Tulokseksi saatiin joustava 6-vaiheinen U-mallinen One-piece flow koulutuslinja, jonka avulla asentajia voidaan kouluttaa sekä One-piece flow että solutuotantomallisesti. Uuden koulutuslinjan työn laajuus -dokumentti toimitettiin toimittajalle sekä lukuisia neuvotteluja käytiin parhaan loppuratkaisun saavuttamiseksi, jonka jälkeen uusi koulutuslinja tilattiin. Lopuksi koostettiin yksityiskohtainen implementointisuunnitelma arvioituineen aikatauluineen ja laadittiin toimenpidelista tulevaisuutta varten. Uusi ratkaisu täyttää asetetut tavoitteet ja eliminoi kaikki ongelmat, hukat ja pullonkaulat sekä takaa turvallisuuden, ergonomian, joustavuuden, selkeän virtauksen ja laadukkaan koulutusprosessin. Uuden ratkaisun myötä koulutuksen ja operaatioiden tehokkuus, laatu ja tuottavuus paranevat

Managerial Practices that Support Lean and Socially Sustainable Working Conditions

Despite decades of using lean, there is little knowledge of how lean managerial practices affect working conditions. Thus, the aim of this study was to investigate in what ways managerial practices support socially sustainable working conditions (SSWCs) during a lean transformation. A mixed methods approach was used in this multiyear case study in a midsize Swedish manufacturing company. Assessment of work characteristics was combined with employee questionnaires and interviews with managers. Four practices were identified as instrumental for SSWCs: 1) a coherent lean approach with clear direction, 2) a value-creating leadership style comprising a participatorypromoting and caring leadership approach with joint focus on production and well-being, 3) conscious involvement of employees in a stepwise fashion, and 4) a focus on promoting meaningful jobs and health, aided by work environment management. Thus, managerial practices actively supporting important job resources as an integral part of the lean system seemed to support SSWCs

Productivity and flexibility improvement of assembly lines for high-mix low-volume production. A white goods industry case

Las tendencias globales de la personalización e individualización en masa impulsan la producción industrial en serie corta y variada; y por tanto una gran variedad de productos en pequeñas cantidades. Por ello, la customización en masa precisa de sistemas de ensamblaje que sean a la vez altamente productivos y flexibles, a diferencia de la tradicional oposición entre ambas características. La llamada cuarta revolución industrial trae diversas tecnologías habilitadoras que podrían ser útiles para abordar este problema. Sin embargo, las metodologías para implementar el ensamblaje 4.0 todavía no han sido resueltas. De hecho, para aprovechar todas las ventajas potenciales de la Industria 4.0, es necesario contar con un nivel previo de excelencia operacional y un análisis holístico de los sistemas productivos. Esta tesis tiene como objetivo entender y definir cómo mejorar la productividad y la flexibilidad de las operaciones de montaje en serie corta y variada.Esta meta se ha dividido en tres objetivos. El primer objetivo consiste en comprender las relaciones entre la Industria 4.0 y las operaciones de ensamblaje, así como sus implicaciones para los operarios. El segundo objetivo consiste en desarrollar una metodología y las herramientas necesarias para evaluar el rendimiento de diferentes configuraciones de cadenas de ensamblaje. El último objetivo consiste en el diseño de sistemas de ensamblaje que permitan incrementar su productividad al menos un 25 %, produciendo en serie corta y variada, mediante la combinación de puestos de montaje manual y estaciones automatizadas.Para abordar la fase de comprensión y definición del problema, se llevó a cabo una revisión bibliográfica sistemática y se desarrolló un marco conceptual para el Ensamblaje 4.0. Se desarrollaron, verificaron y validaron dos herramientas de evaluación del rendimiento: un modelo matemático analítico y varios modelos de simulación por eventos discretos. Para la verificación, y como punto de partida para los análisis, se ha utilizado un caso de estudio industrial de un fabricante global de electrodomésticos. Se han empleado múltiples escenarios de simulación y técnicas de diseño de experimentos para investigar tres cuestiones clave.En primer lugar, se identificaron los factores más críticos para el rendimiento de líneas de montaje manuales multi-modelo. En segundo lugar, se analizó el rendimiento de líneas de montaje semiautomáticas paralelas con operarios móviles en comparación con líneas semiautomáticas o manuales con operarios fijos, empleando diversos escenarios de demanda en serie corta y variada. Por último, se investigó el uso de trenes milkrun para la logística interna de líneas de ensamblaje multi-modelo bajo la influencia de perturbaciones.Los resultados de las simulaciones muestran que las líneas paralelas con operarios móviles pueden superar a las de operarios fijos en cualquier escenario de demanda, alcanzando como mínimo el objetivo de mejorar la productividad en un 25% o más. También permiten reducir cómodamente el número de operarios trabajando en la línea sin afectar negativamente al equilibrado de la misma, posibilitando la producción eficiente de bajo volumen. Los resultados de las simulaciones de logística interna indican que los milkrun pueden proteger las líneas de ensamblaje de las perturbaciones originadas en procesos aguas arriba.Futuras líneas de investigación en base a los resultados obtenidos en esta tesis podrían incluir la expansión e integración de los modelos de simulación actuales para analizar las cadenas de montaje paralelas con operarios móviles incorporando logística, averías y mantenimiento, problemas de control de calidad y políticas de gestión de los retrabajos. Otra línea podría ser el uso de diferentes herramienta para el análisis del desempeño como, por ejemplo, técnicas de programación de la producción que permitan evaluar el desempeño operacional de diferentes configuraciones de cadenas de montaje con operarios móviles, tanto en términos de automatización como de organización en planta. Podrían incorporarse tecnologías de la Industria 4.0 a los modelos de simulación para evaluar su impacto operacional global ¿como cobots para ensamblaje o para la manipulación de materiales, realidad aumentada para el apoyo cognitivo a los operarios, o AGVs para la conducciónde los trenes milkrun. Por último, el trabajo presentado en esta tesis acerca las líneas de ensamblaje semiautomáticas con operarios móviles a su implementación industrial.<br /