Augmented Reality in a Lean Workplace at Smart Factories: A Case Study

Abstract

The last few years have seen a massive transformation of the global industrial landscape, thanks to the emergence of Industry 4.0 and the disruptive technologies it enables, such as Augmented Reality (AR). This paper presents the result of a project with the primary focus on enhancing the operators’ working conditions and the further definition of the most suitable AR for each material handling and motion process. To achieve this, a methodology called Risk Assessment for Ergonomics and Safety in Logistics (RAES-Log) was developed in order to analyse and define AR implementation requirements, in order to mitigate existing risks and improve ergonomic conditions. Utilizing a human-centric approach consistent with Lean Thinking and Industry 5.0 vision, the main aim was to reduce human effort during task performance. Furthermore, the potential for creating waste-free and more efficient workspaces was explored, as well as the possibility of Human Augmentation (HA) to enhance workers’ capabilities and senses. The workers’ opinions and acceptance of the proposed AR solutions resulting from the RAES-Log methodology in a case study were collected and analysed. The overall feedback was positive and it is expected a lower prevalence of work-related Musculoskeletal Disorders (MSD), less lost time days, and lower injury severity, as well as increased process efficiency, operator motivation, well-being and engagement in continuous improvement processes.

Assessment of the Impact of Lean Tools on the Safety of the Shoemaking Industry

“…The new design introduced the "Lean tool" poka-yoke, which prevents operators from stacking cards, thus eliminating safety and ergonomic risks. Pereira et al [19] developed a project whose main objective was to improve operators' working conditions and define the most suitable augmented reality (AR) for each material handling and movement process. To this end, they developed a methodology called risk assessment for ergonomics and safety in logistics (RAES-Log) to analyze and define the requirements for implementing AR so as to mitigate existing risks and improve ergonomic conditions.…”

Promoting safety of underground machinery operators through participatory ergonomics and fuzzy model analysis to foster sustainable mining practices

“…To optimize work process efficiency, it is important to address various factors such as task management, levels of physical exertion, material handling practices, and required mental effort. Researchers emphasize the importance of incorporating these factors into work process design to reduce the likelihood of accidents and enhance overall performance 24 , 25 . Another study carried out by Mirdad 26 , opined to investigate the effects of process redesign on the reduction of strain experienced in lifting occupations.…”

Assessments of Order-Picking Tasks Using a Paper List and Augmented Reality Glasses with Different Order Information Displays

“…AR glasses have been adopted in OP tasks by providing visual guidance information when searching for items in a storage area [17,18]. They allow workers to access logistic information in a hands-free manner [6,14,[19][20][21][22][23][24] and, thus, could improve task efficiency [16,25]. The benefits of AR devices in facilitating OP tasks, however, depend on the hardware and software designs of the device.…”