Ergonomic Evaluation of Manufacturing System Designs

Using high-level, 3-D computer graphics simulation and other engineering analysis tools, this research investigates the ergonomic advantages of one manufacturing system design over another. The designs compared are lean manufacturing (manufacturing cells) and the functional (job shop) design. Simulation models based on an actual manufacturing cell and its workers are used to generate corresponding functional workstations with identically modeled workers. Three ergonomic areas-kilocalorie expenditure, potential for harmful postures, and potential for repetitive motion disorders-are analyzed from simulated and monitored data on energy expenditure, postures, repetitive motion, and other processing functions, such as cycle time. Initial research indicates a substantially lower risk from work-related injuries when using the cellular manufacturing design rather than the functional job shop design; thus, the design of the manufacturing system may inherently reduce or eliminate physiological problems before they develop. In addition, 3-D simulation software with ergonomic analysis functions is shown to be an extremely effective tool for the manufacturing system designer and the ergonomist.