ENVIRONMENT

The Importance of the Work Environment for Improved Manufacturing Performace

Applying the study of Human Factors and Ergonomics (HF/E) to manufacturing can improve human safety, quality, productivity, and operational systems. HF/E as a design-oriented framework for the human workforce, is defined as ‘improving compatibility, effectiveness, safety, ease of performance, human well-being, and quality of life.’ (Reiman et al., 2021). Understanding how poor manufacturing work environments and workstations impact workers and Operators can help reduce mistakes in the workplace, thus creating a safer and more efficient manufacturing environment within the organization. Workers who run robotics or large machinery are known as Operators.

In manufacturing, the application of HF/E principles is focused on three main areas: Where are the Operators working? What are Operators being asked to do? What person is doing the task or work? (Health and Safety Executive, 2021). The relationship between the Operator’s workstation/environment, physical and mental abilities, and the machine is imperative to understanding HF/E.

Where are the Operators working?

To understand how to improve the Operator’s work environment, one must ask, Where are the Operators asked to do their work, and how is their workstation? Asking these questions allows for the framework of improving human safety. When discussing HF/E and enhancing human safety, reach and workspace are crucial considerations. Dr. André Cardoso, a collaborative robotics scholar and expert in ergonomic principles, looked at how "Operators may have to take inappropriate postures to deal with the robot's movements, and, additionally, the Operator moves up from a co-operant role to a position of supervising the work situation." Transitioning the Operator from a co-operant position to overseeing the workstation may incur cognitive costs due to the allocation and reallocation of attentional resources (Cardoso et al., 2021). Having the Operator in inappropriate positions for long periods is not efficient and can cause physical harm and/or pain.

Additionally, Operators may have to share a workstation with a robot or machinery and collaborate in “Independent”, “Simultaneous”, “Sequential” and “Supportive” ways. An operator's task is no longer autonomous if they are supposed to work independently of the robot but must give way to the machine in a cramped workspace. The machine is now under the operator's supervision, and attempting to finish the main task may take longer, squandering time, money, and efficiency.

Examples of independent, Simultaneous, Sequential, and Supportive human-robot collaboration (HRC)

Human-robot collaboration (HRC) with a small workstation raises safety issues, especially concerning collision avoidance, reactive motion planning techniques, and protecting the operator from impending danger or injury brought on by any malfunction or error (Cardoso et al., 2021). The more time an Operator dedicates to these problems, the more challenging it becomes to concentrate on the primary task. HF/E must be considered as a requirement in the deployment of collaborative systems.

Another environmental condition to consider in the workstation is lighting, as it can boost productivity. Appropriate lighting for the Operator is so important that “improving lighting in production shops to meet task demands resulted in a 61% reduction in customer returns.” (Neumann et al., 2016). The improved work environment resulted in a reduction in mistakes made in the workplace due to proper lighting in the workstation. In the context of lighting and HF/E, it is essential to consider the equipment or robots at the workstation. Employing adaptive lighting solutions that ensure adequate illumination for the Operator while minimizing glare that may disrupt robotic vision systems.

What are people being asked to do?

When discussing the operators' or workers' environment, it is important to consider what they are expected or asked to do. Understanding what is being asked of the Operator can further improve performance, as “tasks should be designed in accordance with ergonomic principles to take account of both human limitations and strengths” (Health and Safety Executive, 2021). If proper precautions are not taken, injuries resulting in lost days or ‘lost time injury’ (LTI) can negatively impact productivity.

For example, Dr. Ana Colim, professor of ergonomics and Human Factors in the Department of Production and Systems of the School of Engineering at UMinho, studied a furniture manufacturing company. Within that company, there were 8 workers diagnosed with work-related musculoskeletal disorders (WMSD). WMSD is when “the body uses muscles, tendons, and ligaments to perform tasks, oftentimes in awkward positions or in frequent activities, which can create pain and injury over time. Overexertion and repetitive motion are the primary causes of these injuries.” (U.S. Bureau of Labor Statistics, 2020). Establishing systems that allow operators to take breaks from repetitive motions or employing robots and machinery to perform these tasks enables Operators to concentrate on other responsibilities. Relieving them of repetitive tasks that could cause chronic injuries improves worker safety, productivity, and operational systems. 272,780 workers had been diagnosed with WSMSD in the United States in 2018. Of the 272,780 diagnoses, nearly 40,000 came from the manufacturing industry (U.S. Bureau of Labor Statistics, 2020).

2018 graph of WMSD by selected industries

Colim’s studied work activity “consists of a manual assembly with medium-density fiberboard (MDF) frames where different MDF components are glued. The glue is applied with a hot glue gun activated by a finger trigger.

The tasks are the following:

1. Task 1 (T1): reach for the stripes from a pallet and place them in the assembly work-bench;

2. T2: Pick the blocks (small MDF pieces) from a box;

3. T3: Reach for the glue gun and apply glue to the blocks;

4. T4: Glue the blocks to the stripes;

5. T5: Dislodge the stripes;

6. T6: Transfer the semi-product to the pallet (Colim et al., 2021)”.

Example of repetitive upper arm movements within the furniture manufacturing company.

Who is doing the work?

The final category examined within the Human Factor and Ergonomics scope is, who is doing the work. Matching the task to the limitations and strengths of people further improves the productivity of the products being produced and the quality of products (Health and Safety Executive, 2021). Using the example of the furniture manufacturing company—employing someone who may have arthritis is not a suitable choice, as a hot glue gun is used for the furniture and is activated by a finger trigger. The mental aspects that should be considered are perceptual, attentional, and decision-making requirements (Health and Safety Executive, 2021). The physical traits to consider would be size and strength, dexterity, sensory abilities, and posture (Mowla, Laila, et al., 2021). By considering physical aspects, you reduce the physical strain and improve the productivity of operators and system performances.

The application of Human Factors and Ergonomics (HF/E) in manufacturing enhances the compatibility between machines and Operators, thereby improving human safety, productivity, and operational systems. Organizations can increase productivity, improve quality by lowering operational errors, and significantly reduce workplace injuries through a thorough understanding and optimization of the relationship between the operator, the workstation, and the machines they interact with. The insights into workstation design, task structuring, and worker capabilities highlight the importance of creating environments that align with physical and cognitive demands. From improving ergonomics to addressing repetitive task-related injuries and optimizing lighting conditions, integrating HF/E principles fosters a safer, more efficient manufacturing environment. Ultimately, by tailoring tasks to human strengths, reducing mental and physical strain, and supporting worker well-being, manufacturers can enhance operational systems and increase both productivity and job satisfaction.

Summary 

• HF/E improves human safety, quality, productivity, and operational systems.

• HF/E Focuses on understanding the impact of work environments and workstations on workers (Operators) to reduce mistakes, enhance safety, and improve efficiency.

• Three Areas of Focus:

1. Where are Operators working?

2. What are Operators being asked to do?

3. Who is doing the work?

• The relationship between the workstation, physical/mental abilities, and machines is critical for understanding HF/E.

• It’s crucial to match tasks to workers' physical and mental capabilities. Consideration of physical traits such as strength, dexterity, and sensory abilities can reduce physical strain and improve productivity.

Benefits of HF/E Application:

• Enhances the compatibility between machines and workers, improving safety, productivity, and operational systems.

• Reduces workplace injuries, operational errors, and inefficiencies, leading to increased quality and job satisfaction.

• Aligning work environments with human capabilities boosts performance and reduces strain.

• By applying HF/E principles, manufacturers can create safer, more efficient work environments that enhance both human well-being and operational success.