A prototype safety system for new on-the-job training (OJT) in an anthropocentric cell manufacturing system

Abstract

The anthropocentric cell manufacturing system (ACMS) discussed consists of a skill-based manufacturing scheduling system, a new on-the-job training (New OJT) system and a safety system. The New OJT was developed using e-learning and automated guided vehicle (AGV)-arm robot as a teacher for CNC machine training. Since the machines and the AGV-arm robot are automatic devices, controlled by computer programs, the dangers might arise during training. Therefore, the safety system is required to ensure that a learner will be safe. We propose a prototype of safety system with designed machine-protection in order to protect the learner from dangerous behaviours during a level 1 training of a New OJT in ACMS. The machine-protection focused on protection from danger using image processing with a background subtraction technique and comparison of objects’ position. We also evaluated safety assessments of the learners, consisting of human error probabilities (HEP) and a human error rate (HER). The prototype of this developed safety system showed that the machine-protection certainly raises a warning alarm when the learner rises into dangerous zones during the training. The evaluated safety assessments showed that our designed New OJT training level 1 course performed more efficient safety performance for self-training of the learner.

Keywords:

• safety system
• safety engineering
• human error
• safety assessments
• image processing
• background subtraction