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DEVELOPMENT OF A NEW ASSEMBLY LINE BALANCE MODEL UNDER ERGONOMIC RISK CONSTRAINTS

Year 2018, , 49 - 57, 24.12.2018
https://doi.org/10.21923/jesd.363560

Abstract

Assembly
line balancing is the problem to assign tasks to stations in compliance with
precedence constraints and as far as possible to balance delays. Assembly lines
which is not designed properly in an ergonomic way, not only cause productivity
loss, but also Work-related Muscoloskeletal Disorders (WSMD) on workers. To
prevent such problems, it should aimed to catch acceptable level for all
workstation’s total risk score and assign ergonomic risks equivalently among
workers.
In
this study, for assembly line balancing problem, a new model approach is
tackled, which constitute stations by consider ergonomic risk levels in
addition to cycle time and precedence constraints.
Moreover in order to compare proposed model with
classical assembly line balancing techniques, a performance criteria which is
combination of cycle time and ergonomic risk level is defined. The developed
model were applied in three different factory’s assembly lines. In every two
assembly lines, task times were measured, precedence diagram was constructed
and ergonomic risk levels were evaulated by using REBA method. When balancing
lines with using COMSOAL technique, performance level is %28,56 but when it comes
to balance with developed model performance levels were obtained %25,22. It has
been detected that developed model provides improvement in line’s performance %3,34.

References

  • Akyol, ¸ S. D., Baykasoglu, A., 2016. ErgoALWABP: A multiple-rule based constructive randomized search algorithm for solving assembly line worker assignment and balancing problem under ergonomic risk factors. Journal of Intelligent Manufacturing. doi:10.1007/s10845-016-1246-6
  • Baines, T.S., Asch, R., Hadfield, L., Mason, J.P., Fletcher, S., Kay, J.M., 2005. Towards a theoretical framework for human performance modelling within manufacturing systems design. Simulation Modelling Practice and Theory, 13, 486–504.
  • Baykasoglu, A., Tasan, S.O., Tasan, A.S., Akyol, S., 2017. Modeling and solving assembly line design problems by considering human factors with a real-life application. Human Factors and Ergonomics in Manufacturing & Service Industries, 27(2), 96-115.
  • Bernard, B. P., 1997. Musculoskeletal disorders and workplace factors: A critical review of epidemiologic evidence for work-related musculoskeletal disorders of the neck, upper extremity and low back pain, U.S Department of Health and Human Services NIOSH Publication, 97-141.
  • David, G. C. 2005. Ergonomic methods for assessing exposure to risk factors for work-related musculoskeletal disorders. Occupational Medicine, 55, 190-199.
  • Digiesi, S., Kock, A. A. A., Mummolo, G., & Rooda, J. E., 2009. The effect of dynamic worker behaviour on flow time performance. International Journal of Production Economics, 120, 368–377.
  • Eklund, J. A. E., 1995. Relationships between ergonomics and quality in assembly works. Applied Ergonomics, 26 (1), 15-20.
  • Güner, B., Hasgül, S. , 2012. Sürdürülebilir denge için ergonomik faktörleri içeren U-tipi montaj hattı dengelemesi. Gazi Üniversitesi Mühendislik Mimarlık Fakültesi Dergisi, 27(2), 407-415.
  • Hignett, S., Mc Atamney, L. 2000. Rapid entire body assessment (REBA). Applied Ergonomics, 31, 201–205.
  • Koç, S. , Testik, Ö.M. 2016. Mobilya Sektöründe Yaşanan Kas-İskelet Sistemi Risklerinin Farklı Değerlendirme Metotları İle İncelenmesi Ve Minimizasyonu. Endüstri Mühendisliği Dergisi, 27(2), 2-27.
  • Mert, E. A. 2014. Ergonomik risk değerlendirme yöntemlerinin karşılaştırılması ve bir çanta imalat atölyesinde uygulanması. İş Sağlığı ve Güvenliği Uzmanlık Tezi, T.C. Çalışma ve Sosyal Güvenlik Bakanlığı İş Sağlığı ve Güvenliği Genel Müdürlüğü, Ankara.
  • Mutlu, Ö., Özgörmüş, E. 2012. A fuzzy assembly line balancing problem with physical workload constraints. International Journal of Production Research, 50, 5281-5291.
  • Nunes, I. L. 2009. FAST ERGO_X – a tool for ergonomic auditing and work-related musculoskeletal disorders prevention. Work: A Journal of Prevention, Assessment & Rehabilitation, 34, 133–148.
  • Otto, A., Scholl, A., 2011. Incorporating ergonomic risks into assembly line balancing. European Journal of Operational Research, 212, 277–285.
  • Özel, E., Çetik, O. 2010. Mesleki Görevlerin Ergonomik Analizinde Kullanılan Araçlar ve Bir Uygulama Örneği. Dumlupınar Üniversitesi Fen Bilimleri Enstitüsü Dergisi, 22, 41-56.
  • Salveson, M.E., 1955. The assembly line balancing problem. Journal of Industrial Engineering, 6,18–25.
  • Scholl, A., Becker, C., 2006. State-of-the-art exact and heuristic solution procedures for simple assembly line balancing. European Journal of Operational Research, 168(3), 666–693.
  • Seçkiner, S. U., Kurt, M., 2007. A simulated annealing approach to the solution of job rotation scheduling problems. Applied Mathematics and Computation, 188, 31–45.
  • Tharmmaphornphilas, W., & Norman, B. A., 2007. A methodology to create robust job rotation schedules. Annals of Operations Research, 155, 339–360.
  • Xu, Z., Ko, J., Cochran, D. J., Jung, M., 2012. Design of assembly lines with the concurrent consideration of productivity and upper extremity musculoskeletal disorders using linear models. Computers & Industrial Engineering, 62, 431–441.

ERGONOMİK RİSK KISITLARI ALTINDA YENİ BİR MONTAJ HATTI DENGELEME MODELİ GELİŞTİRİLMESİ

Year 2018, , 49 - 57, 24.12.2018
https://doi.org/10.21923/jesd.363560

Abstract

Montaj hattı dengeleme probleminde işler,
öncelik ilişkilerine uygun olarak gecikmeleri olabildiği ölçüde dengeleyecek
şekilde istasyonlara atanır. Ergonomik anlamda iyi tasarlanmamış montaj
hatları, yalnızca verimlilik kayıplarına sebep olmakla kalmaz, işçilerde kas
iskelet sistemi hastalıklarına da yol a
çabilir.
Böyle olumsuzlukları önlemek i
çin
montaj hattını dengelerken her bir istasyonun risk seviyesinin kabul edilebilir
seviyeye çekilmesi veya zorluk düzeyinin işçiler arasında dengeli olması da
amaçlanmalıdır. Bu
çalışmada,
montaj hattı dengelemede, öncelik ilişkileri ile çevrim süresi kısıtına
ilaveten, regonomik risk düzeyini de dikkate alarak istasonları oluşturan yeni
bir model geliştirilmesi ele alınmıştır. Ayrıca, önerilen modelin klasik montaj
hattı dengeleem ile karşılaştırılması amacıyla, süre ve ergonomik risk
düzeyinin bileşkesinden oluşan performans ölçütü tanımlanmıştır. Geliştirilen
model, fırın üreten işletmenin  montaj
hattı için uygulanmıştır. Her iki montaj hattında işlem süreleri ölçülmüş,
öncelik ilişkileri çıkarılmış ve REBA yöntemi ile ergonomik risk düzeyleri
hesaplanmıştır. COMSOAL yöntemi kullanılarak yapılan hat dengelemede,  performans düzeyleri, %28,56 olurken,
geliştirilen model için %25,22 elde edilmiştir. Geliştirilen modelin %3,34 iyileştirme
sağladığı tesbit edilmiştir.

References

  • Akyol, ¸ S. D., Baykasoglu, A., 2016. ErgoALWABP: A multiple-rule based constructive randomized search algorithm for solving assembly line worker assignment and balancing problem under ergonomic risk factors. Journal of Intelligent Manufacturing. doi:10.1007/s10845-016-1246-6
  • Baines, T.S., Asch, R., Hadfield, L., Mason, J.P., Fletcher, S., Kay, J.M., 2005. Towards a theoretical framework for human performance modelling within manufacturing systems design. Simulation Modelling Practice and Theory, 13, 486–504.
  • Baykasoglu, A., Tasan, S.O., Tasan, A.S., Akyol, S., 2017. Modeling and solving assembly line design problems by considering human factors with a real-life application. Human Factors and Ergonomics in Manufacturing & Service Industries, 27(2), 96-115.
  • Bernard, B. P., 1997. Musculoskeletal disorders and workplace factors: A critical review of epidemiologic evidence for work-related musculoskeletal disorders of the neck, upper extremity and low back pain, U.S Department of Health and Human Services NIOSH Publication, 97-141.
  • David, G. C. 2005. Ergonomic methods for assessing exposure to risk factors for work-related musculoskeletal disorders. Occupational Medicine, 55, 190-199.
  • Digiesi, S., Kock, A. A. A., Mummolo, G., & Rooda, J. E., 2009. The effect of dynamic worker behaviour on flow time performance. International Journal of Production Economics, 120, 368–377.
  • Eklund, J. A. E., 1995. Relationships between ergonomics and quality in assembly works. Applied Ergonomics, 26 (1), 15-20.
  • Güner, B., Hasgül, S. , 2012. Sürdürülebilir denge için ergonomik faktörleri içeren U-tipi montaj hattı dengelemesi. Gazi Üniversitesi Mühendislik Mimarlık Fakültesi Dergisi, 27(2), 407-415.
  • Hignett, S., Mc Atamney, L. 2000. Rapid entire body assessment (REBA). Applied Ergonomics, 31, 201–205.
  • Koç, S. , Testik, Ö.M. 2016. Mobilya Sektöründe Yaşanan Kas-İskelet Sistemi Risklerinin Farklı Değerlendirme Metotları İle İncelenmesi Ve Minimizasyonu. Endüstri Mühendisliği Dergisi, 27(2), 2-27.
  • Mert, E. A. 2014. Ergonomik risk değerlendirme yöntemlerinin karşılaştırılması ve bir çanta imalat atölyesinde uygulanması. İş Sağlığı ve Güvenliği Uzmanlık Tezi, T.C. Çalışma ve Sosyal Güvenlik Bakanlığı İş Sağlığı ve Güvenliği Genel Müdürlüğü, Ankara.
  • Mutlu, Ö., Özgörmüş, E. 2012. A fuzzy assembly line balancing problem with physical workload constraints. International Journal of Production Research, 50, 5281-5291.
  • Nunes, I. L. 2009. FAST ERGO_X – a tool for ergonomic auditing and work-related musculoskeletal disorders prevention. Work: A Journal of Prevention, Assessment & Rehabilitation, 34, 133–148.
  • Otto, A., Scholl, A., 2011. Incorporating ergonomic risks into assembly line balancing. European Journal of Operational Research, 212, 277–285.
  • Özel, E., Çetik, O. 2010. Mesleki Görevlerin Ergonomik Analizinde Kullanılan Araçlar ve Bir Uygulama Örneği. Dumlupınar Üniversitesi Fen Bilimleri Enstitüsü Dergisi, 22, 41-56.
  • Salveson, M.E., 1955. The assembly line balancing problem. Journal of Industrial Engineering, 6,18–25.
  • Scholl, A., Becker, C., 2006. State-of-the-art exact and heuristic solution procedures for simple assembly line balancing. European Journal of Operational Research, 168(3), 666–693.
  • Seçkiner, S. U., Kurt, M., 2007. A simulated annealing approach to the solution of job rotation scheduling problems. Applied Mathematics and Computation, 188, 31–45.
  • Tharmmaphornphilas, W., & Norman, B. A., 2007. A methodology to create robust job rotation schedules. Annals of Operations Research, 155, 339–360.
  • Xu, Z., Ko, J., Cochran, D. J., Jung, M., 2012. Design of assembly lines with the concurrent consideration of productivity and upper extremity musculoskeletal disorders using linear models. Computers & Industrial Engineering, 62, 431–441.
There are 20 citations in total.

Details

Primary Language Turkish
Subjects Engineering
Journal Section ÖS: ERGONOMI2017
Authors

Emin Kahya 0000-0001-9763-2714

Büşra Nur Şahin This is me 0000-0002-4963-5483

Esra Daşdelen This is me 0000-0001-9763-2714

Seda Doğru This is me 0000-0001-9763-2714

Publication Date December 24, 2018
Submission Date December 7, 2017
Acceptance Date June 8, 2018
Published in Issue Year 2018

Cite

APA Kahya, E., Şahin, B. N., Daşdelen, E., Doğru, S. (2018). ERGONOMİK RİSK KISITLARI ALTINDA YENİ BİR MONTAJ HATTI DENGELEME MODELİ GELİŞTİRİLMESİ. Mühendislik Bilimleri Ve Tasarım Dergisi, 6, 49-57. https://doi.org/10.21923/jesd.363560