An integrated ergonomic risk assessment framework based on fuzzy logic and IVSF-AHP for optimising ergonomic risks in a mixed-model assembly line

Abstract

This study proposes a systematic approach to address ergonomic factors, including physical, environmental and psychosocial aspects, in solving assembly line balancing problems. A three-stage framework is developed, starting with determining weights for ergonomic risk assessment methods using the interval-valued spherical fuzzy analytical hierarchy process. In the second stage, a fuzzy logic model for integrated ergonomic risk assessment is constructed based on these weights, and the integrated ergonomic risk score is determined. In the third stage, a mathematical model is formulated to minimise the cycle time while balancing the ergonomic risk level. A case study conducted in a wire harness factory validated the effectiveness of the proposed approach, showing a 10–11% improvement in line efficiency and a 12–25% enhancement in ergonomic risk balancing performance. These findings underscore the potential benefits of implementing this approach, which can significantly improve occupational safety and overall performance.

Practitioner Summary

This article presents a practical and systematic approach for enhancing ergonomic conditions in assembly lines. The proposed approach aims to balance the ergonomic risk level while minimising the cycle time by considering physical, environmental and psychosocial risk factors. A case study conducted in a wire harness factory demonstrated significant improvements in balancing ergonomic risks, highlighting the real-world applicability of this research.

Keywords:

• Ergonomic risk assessment
• fuzzy logic
• mixed-integer programming
• mixed-model assembly line balancing

Acknowledgements

The authors are grateful to all the participants for their support and participation in this study.

Informed consent

Informed consent was obtained from all study participants in accordance with Personal Data Protection Law No. 6698. Each participant provided consent through a separately prepared petition that met the requirements of the law.

Disclosure statement

No potential conflict of interest was reported by the author(s).

Additional information

Funding

This research received no specific grant from funding agencies in the public, commercial, or not-for-profit sectors.