Integration of human factors and ergonomics into lean implementation: ergonomic-value stream map approach in the textile industry

Nagaraj, T. S.; Jeyapaul, R.; Vimal, K.E.K.; Mathiyazhagan, K.

doi:10.1080/09537287.2019.1612109

Cited by 44 publications

(29 citation statements)

References 58 publications

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“…On the same topic, Nagaraj et al [10] argued that this integrated approach decreases the adverse effects of lean on the workers' quality of life, improving operational efficiency (such as workers' performance, value-added ratio, errors' reduction). Lean and Ergonomics can reduce lead time by eliminating waste from non-productive manual materials handling and awkward postures as well as increasing workers' effectiveness, safety and health [11,12].…”

Section: Introduction 1sinergy Between Lean Manufacturing and Ergonomentioning

confidence: 99%

Lean Manufacturing and Ergonomics Integration: Defining Productivity and Wellbeing Indicators in a Human–Robot Workstation

Colim¹,

Morgado

Carneiro

et al. 2021

Sustainability

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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.

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Section: Introduction 1sinergy Between Lean Manufacturing and Ergonomentioning

confidence: 99%

Lean Manufacturing and Ergonomics Integration: Defining Productivity and Wellbeing Indicators in a Human–Robot Workstation

Colim¹,

Morgado

Carneiro

et al. 2021

Sustainability

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“…As a result, the prevalence of occupational accidents and injuries is high in developing countries such as India. In India, there exists a void in understanding the significance of ergonomic issues and its influence on the production capacity of the manufacturing sector [20].…”

Section: Introductionmentioning

confidence: 99%

Role of Ergonomic Factors Affecting Production of Leather Garment-Based SMEs of India: Implications for Social Sustainability

et al. 2020

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This paper aims to identify, evaluate, and measure the ergonomic factors hampering the production of leather garment-based small and medium-sized enterprises (SMEs). Ergonomic problems faced by the workers largely impact the health of individuals and also the productivity of a firm. Based on experts’ opinions and a literature survey, three emerging categories—namely, occupational disease, personal factors, and the industrial environment—with a total of twenty factors were identified to examine symmetrical impact in five leather garment companies. In this research work, Cronbach’s α was evaluated to check the validity of the ergonomic factors identified through the literature survey. Then, using the fuzzy analytic hierarchy process (FAHP), the identified ergonomic factors were evaluated. A sensitivity analysis was carried out to validate the robustness of the results obtained using the integrated approach. Outdated machinery, vibration, operational setup, fatigue, and poor ventilation and lighting are the top five factors inducing ergonomic-related problems and hampering the production of the leather garment companies in India. These top ergonomic factors are the result of a failure in the provision of an ambient working environment. Providing ergonomically designed working environments may lower the occurrence of ergonomic problems. The findings of this study will assist industrial managers to enhance production rate and to progress towards social sustainability in Indian SMEs. The proposed symmetrical assessment in this study could also be considered as a benchmark for other companies in which human–machine interaction is significant.

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“…Both present methodologies similarities in the first two steps, coinciding in the importance of preparing the project and selecting key indicators and team members. After building the current state, Rother and Shook (2009) indicate that an analysis of the information gathered must be carried out to define the desired future state before making changes to the processes, while Sakthi et al (2019) opted for defining the improvement plan after building the current state of the process based on the data obtained and the areas of opportunity identified while mapping the current state. This change by Sakthi et al (2019) that consists of not defining the future state stands out against the importance that Rother & Shook (2009) give to defining the desired future state by considering it the guideline that helps define improvement actions that will help us get closer to what the value flow should be.…”

Section: Future State Definitionmentioning

confidence: 99%

“…After building the current state, Rother and Shook (2009) indicate that an analysis of the information gathered must be carried out to define the desired future state before making changes to the processes, while Sakthi et al (2019) opted for defining the improvement plan after building the current state of the process based on the data obtained and the areas of opportunity identified while mapping the current state. This change by Sakthi et al (2019) that consists of not defining the future state stands out against the importance that Rother & Shook (2009) give to defining the desired future state by considering it the guideline that helps define improvement actions that will help us get closer to what the value flow should be. emphasize the importance of evaluating the future state before implementing the changes to know if the desired indicator improvements will be achieved and present the future state mapping to all the workers to help generate more improvement ideas and ensure the staff's participation in the action plan.…”

Section: Future State Definitionmentioning

confidence: 99%

“…Additional to the countries mentioned above, this council is made up of Finland, Norway, the Faroe Islands, Greenland, and Åland, and their goal is to make this region the most sustainable and integrated of the planet (The Nordic Council and the Nordic Council of Ministers, 2018). ErgoVSM is identified as a recently discovered tool outside of the Nordic council, and it started to be used in 2013 in countries such as Brazil (Pereiro da Silva & Goncalves-Amaral, 2019), United States (Aqlan et al, 2013), United Arab Emirates (Kim, 2017), Indonesia (Suryoputro et al, 2017), India (Sakthi et al, 2019) and Mexico (Arce et al, 2018;López-Acosta et al, 2019).…”

Section: Distribution By Country Year and Typementioning

confidence: 99%

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ErgoVSM: A new tool that integrates ergonomics and productivity

Dominguez-Alfaro¹,

Mendoza-Muñoz²,

González³

et al. 2021

JIEM

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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 time.

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Integration of human factors and ergonomics into lean implementation: ergonomic-value stream map approach in the textile industry

Cited by 44 publications

References 58 publications

Lean Manufacturing and Ergonomics Integration: Defining Productivity and Wellbeing Indicators in a Human–Robot Workstation

Lean Manufacturing and Ergonomics Integration: Defining Productivity and Wellbeing Indicators in a Human–Robot Workstation

Role of Ergonomic Factors Affecting Production of Leather Garment-Based SMEs of India: Implications for Social Sustainability

ErgoVSM: A new tool that integrates ergonomics and productivity

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