A tool to predict physical workload and task times from workstation layout design data

Abstract

This paper presents the development and proof of concept of a tool to predict worker and system performance using inputs of work element descriptions and hand locations from a seated, light assembly workstation layout. Tool inputs can be obtained in the design stage. Tool outputs include human factors (shoulder load, hand movement, reach zone acceptability) and system (element time and cycle time) information. Shoulder loads are predicted from two-dimensional shoulder models created from a digital human model. The tool is demonstrated on a previous observation-based assessment of a workstation redesign. Results reflected the findings of the observation assessment, but also provided more work cycle information as well as cumulative, work shift information. The tool enables prediction of workload and task performance times from design stage parameters without the need of an ergonomist. It can be used to predict critical components of the layout and plan workflow based on worker, workstation and task information. The tool is available for free downloaded at: www.researchgate.net/project/Workstation-Efficiency-Evaluator-WEE-Tool.

Keywords:

• virtual tool
• shoulder load
• light assembly
• workstation design
• worker health
• human factors
• performance measures
• ergonomics
• work measurement

Acknowledgements

This research would not have been possible without the financial assistance from the Natural Sciences and Engineering Research Council of Canada, the Workplace Safety and Insurance Board of Ontario and the combined financial and in-kind assistance from the industry research partner. The authors are appreciative of their assistance.

Additional information

Funding

This work was supported by the Natural Sciences and Engineering Research Council of Canada [grant number 341664], the Workplace Safety and Insurance Board of Ontario [grant number 09036] and an industry research partner.