The case for the development of novel human skills capture methodologies

As the capabilities of industrial automation are growing, so is the ability to supplement or replace the more tacit, cognitive skills of manual operators. Whilst models have been published within the human factors literature regarding automation implementation, they neglect to discuss the initial capture of the task and automation experts currently lack a formal tool to assess feasibility. The definition of what is meant by "human skill" is discussed and three crucial theoretical underpinnings are proposed for a novel, automation-specific skill capture methodology: emphasis upon procedural rules, emphasis upon action-facilitating factors and taxonomy of skill

The limitations of using only CAD and DHM in design relating to high value manufacturing

The ergonomics suites available within computer aided design and digital human modelling programs are increasingly being used to predict and prevent ergonomic and human factors risk due to poor design. To further aid the reduction in poor design, it is of importance to understand the need for user input and the limitations of these software programs. These limitations include: the small number of available anthropometric population samples; and the disconnect between what a designer perceives as possible, and what is possible within a manufacturing environment. A method of mitigating these limitations is the use of user input using virtual reality suites, mock-ups and motion capture technology

Applying Design for Assembly Principles in Computer Aided Design to Make Small Changes that Improve the Efficiency of Manual Aircraft Systems Installations

The installation of essential systems into aircraft wings involves numerous labour-intensive processes. Many human operators are required to perform complex manual tasks over long periods of time in very challenging physical positions due to the limited access and confined space. This level of human activity in poor ergonomic conditions directly impacts on speed and quality of production but also, in the longer term, can cause costly human resource problems from operators' cumulative development of musculoskeletal injuries. These problems are exacerbated in areas of the wing which house multiple systems components because the volume of manual work and number of operators is higher but the available space is reduced.To improve the efficiency of manual work processes which cannot yet be automated we therefore need to consider how we might redesign systems installations in the enclosed wing environment to better enable operator access and reduce production time.This paper describes a recent study that applied design for assembly and maintainability principles and CATIA v5 computer aided design software to identify small design changes for wing systems installation tasks. Results show positive impacts for ergonomics, production time and cost, and maintainability, whilst accounting for aircraft performance and machining capabilities

Human-automation collaboration in manufacturing: identifying key implementation factors

Human-automation collaboration refers to the concept of human operators and intelligent automation working together interactively within the same workspace without conventional physical separation. This concept has commanded significant attention in manufacturing because of the potential applications, such as the installation of large sub-assemblies. However, the key human factors relevant to human-automation collaboration have not yet been fully investigated. To maximise effective implementation and reduce development costs for future projects these factors need to be examined. In this paper, a collection of human factors likely to influence human-automation collaboration are identified from current literature. To test the validity of these and explore further factors associated with implementation success, different types of production processes in terms of stage of maturity are being explored via industrial case studies from the project’s stakeholders. Data was collected through a series of semi-structured interviews with shop floor operators, engineers, system designers and management personnel

Your new colleague is a robot. Is that ok?

Human robot collaboration is a concept under development that will be applied within manufacturing environments in the near future to increase efficiency and quality. While there have been significant advances in technology to enable this progress there is still little known about the wider human factors issues of employing such systems in High Value Manufacturing environments. This paper sets out our current understanding of key organisational and individual factors which need to be explored

The development of a Human Factors Readiness Level tool for implementing industrial human-robot collaboration

The concept of industrial human-robot collaboration (HRC) is becoming increasingly attractive as a means for enhancing manufacturing productivity and product. However, due to traditional preventive health and safety standards, there have been few operational examples of true HRC, so it has not been possible to explore the organisational human factors that need to be considered by manufacturing organisations to realise the benefits of industrial HRC until recently. Charalambous, Fletcher and Webb (2015) made the first attempt to identify the key organisational human factors for the successful implementation of industrial HRC through an industrial exploratory case study. This work enabled (i) development of a theoretical framework of key organisational human factors relevant to industrial HRC and (ii) identification of these factors as enablers or barriers. Although identifying the key organisational human factors (HF) was an important step, it presented a crucial question: when should practitioners involved in HRC design and implementation consider these factors? New industrial processes are typically designed and implemented using a maturity or readiness evaluation system, but these do not incorporate of or link to any formal considerations of HF. The aim of this paper is to expand on the previous findings and link the key human factors in the theoretical framework directly to a recognised industrial maturity readiness level system to develop a new Human Factors Readiness Level (HFRL) tool for system design practitioners to optimise successful implementation of industrial HRC

Automating human skills : preliminary development of a human factors methodology to capture tacit cognitive skills

Despite technological advances in intelligent automation, it remains difficult for engineers to discern which manual tasks, or task components, would be most suitable for transfer to automated alternatives. This research aimed to develop an accurate methodology for the measurement of both observable and unobservable physical and cognitive activities used in manual tasks for the capture of tacit skill. Experienced operators were observed and interviewed in detail, following which, hierarchical task analysis and task decomposition methods were used to systematically explore and classify the qualitative data. Results showed that a task analysis / decomposition methodology identified different types of skill (e.g. procedural or declarative) and knowledge (explicit or tacit) indicating this methodology could be used for further human skill capture studies. The benefit of this research will be to provide a methodology to capture human skill so that complex manual tasks can be more efficiently transferred into automated processes

Task analysis of discrete and continuous skills: a dual methodology approach to human skills capture for automation

There is a growing requirement within the field of intelligent automation for a formal methodology to capture and classify explicit and tacit skills deployed by operators during complex task performance. This paper describes the development of a dual methodology approach which recognises the inherent differences between continuous tasks and discrete tasks and which proposes separate methodologies for each. Both methodologies emphasise capturing operators’ physical, perceptual, and cognitive skills, however, they fundamentally differ in their approach. The continuous task analysis recognises the non-arbitrary nature of operation ordering and that identifying suitable cues for subtask is a vital component of the skill. Discrete task analysis is a more traditional, chronologically ordered methodology and is intended to increase the resolution of skill classification and be practical for assessing complex tasks involving multiple unique subtasks through the use of taxonomy of generic actions for physical, perceptual, and cognitive actions

The use of job aids for visual inspection in manufacturing and maintenance

Visual inspection is a task regularly seen in manufacturing applications and is still primarily carried out by human operators. This study explored the use of job aids (anything used to assist the operator with the task, such as lists, check sheets or pictures) to assist with visual inspection within a manufacturing facility that inspects used parts. Job aids in the form of inspection manuals were used regularly during the inspection process, and how accurately they were followed was dependent on a number of factors such as size of part, experience of the operator, and accuracy of the inspection manuals. If the job aids were well structured, well written and accessible, then the inspectors were seen to follow them, however for certain jobs inspectors were seen to change the inspection order making inspection more efficient. The findings of the study suggest that prior experience can help in designing efficient, easy to use job aids and that a collaborative approach to design as well as using pictorial examples for comparison purposes would improve the inspection process