Session: 02-02-01: Design, Modeling and Systems

Paper Number: 113495

113495 - Warehouse and Logistics Ergonomics Optimization Through Real-Time Evaluation of the NIOSH Index 

Logistic activities can be physically demanding and cause long-term musculoskeletal problems for operators. Repetitive and incorrect movements, along with heavy loads and uncomfortable positions of objects to be moved, are risk factors for operator’s health. To prevent these risks, ergonomic evaluations are often carried out in the field, where ergonomist carefully observe the actions of the operators, evaluate their movements and loads moved. Furthermore, once a risk assessment has been conducted, a plan to optimize workstations and work processes must be implemented to improve operator ergonomics. Literature shows several methods for automatic evaluation of ergonomic indices, either through virtual simulations or based on real case studies. The aim of these methods is to identify ergonomic problems and suggest solutions to improve operators’ working conditions. Other studies, instead, show frameworks for optimizing workstations, components used during task execution, and the reorganization of warehouse logistics to improve and ease the tasks to be performed. However, the evaluation of ergonomics in real-world case studies and the optimization activities are often disconnected. Optimization is typically carried out through digital human modeling and simulation tools, such as Siemens Jack, IPS IMMA, and Santos. These solutions can provide valuable insights based on empirical data gathered from observations of tests conducted in the field. By the way, their limitations appear when trying to mimic a real work environment or the abilities and limitations of the operator. Therefore, this research work presents a new approach that allows integrating both ergonomic evaluation and optimization in real-world scenarios. This approach shown in the paper provides a more accurate representation of the actual work environment and ensure that the solutions implemented are practical and effective for the operator. In a previous work, a semi-immersive environment system was developed that could simulate a warehouse, with the ability to optimize logistics from an ergonomic standpoint for the operator. The optimization took into account the design of the workplace, the weight of the object to be moved and the lifting frequency of the task. The methodology employed in this prior research work, is applied on a real case study, keeping unchanged the tools and the evaluation methods, the NIOSH lifting equation. The solution developed for this study is applied to the ergonomic analysis of a logistics case study in a company that produces mechanical components, collaborating within JoiintLab, a combined laboratory between the Italian Institute of Technology and Intellimech (a consortium of high-tech enterprises dedicated to the interdisciplinary research in the mechatronics field). This is achieved through the real-time measurement of the NIOSH index, using a motion capture system and an interactive interface that displays the digital twin of the analyzed system. To enhance the working conditions of the operator, an optimization method for the parameters of the analyzed warehouse has been introduced. This solution is based on the recordings made during the tests and provides recommendations for improving the overall ergonomics of the workspace. This contributes significantly to the health and well-being of the workers while improving the overall efficiency and productivity of the logistics system. Finally, the paper concludes with a discussion of the results obtained from the application of the method to the case study.

Presenting Author: Daniel Lanzoni UNIVERSITY OF BERGAMO - DIGIP DEPT.

Presenting Author Biography: PhD candidate in Technology, Innovation and Management in collaboration with the Italian Institute of Technology (IIT). The research focuses on the analysis of human-robot interactions with particular attention to the working conditions of the operator, both from a physical (physical ergonomics) and mental (cognitive ergonomics) point of view. The technologies used in this field are Mixed Reality devices, Motion Capture systems, and wearable sensors for the detection of physiological signals.

Authors:

Daniel Lanzoni UNIVERSITY OF BERGAMO - DIGIP DEPT.
Francesca Negrello Italian Institute of Technology
Andrea Vitali UNIVERSITY OF BERGAMO - DIGIP DEPT.
Daniele Regazzoni UNIVERSITY OF BERGAMO - DIGIP DEPT.
Manuel G. Catalano Italian Institute of Technology
Caterina Rizzi UNIVERSITY OF BERGAMO - DIGIP DEPT.