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Advances in Manufacturing Ergonomics

A special issue of Applied Sciences (ISSN 2076-3417). This special issue belongs to the section "Applied Biosciences and Bioengineering".

Deadline for manuscript submissions: 20 December 2024 | Viewed by 6735

Special Issue Editors

Dr. Alessandro Naddeo

E-Mail Website
Guest Editor
Department of Industrial Engineering, University of Salerno, 84084 Fisciano, Italy
Interests: industrial design methods; computer-aided design; virtual prototyping; human factors and ergonomics; comfort assessment; design for ergonomics; biomechanics; human-centred design; digital human modelling; computer aided surgery
Special Issues, Collections and Topics in MDPI journals
Dr. Rosaria Califano

E-Mail Website
Guest Editor
Department of Industrial Engineering, University of Salerno, 84084 Fisciano, Italy
Interests: industrial design methods; computer-aided design; virtual prototyping; human factors and ergonomics; comfort assessment; design for ergonomics; biomechanics; human-centred design; digital human modelling; computer aided surgery

Special Issue Information

Dear Colleagues,

In recent years, Industry 4.0 has brought rapid technological growth and development in manufacturing industries. Emerging concepts and technologies, such as human–robot collaboration (HRC), augmented and virtual reality (AR/VR), cyber-physical systems (CPSs), the Internet of Things (IoT), and nanotechnology, will constitute the future working environments. Technological development enables efficient manufacturing processes, but also requires the reorganization of work, which may create new threats to employee well-being and challenge their existing skills and knowledge. Therefore, it is crucial to align the advanced technologies in manufacturing to human factors. This Special Issue emphasizes the need for technology to be advanced in tandem with human involvement and empowerment. “Design for all” requirements need to be always applied as if everyone of us is disabled (having the meaning of “differently abled”); this Special Issue will host contributions that explore the new challenges in interactions between humans and 5.0 technologies.

Prof. Dr. Alessandro Naddeo
Dr. Rosaria Califano
Guest Editors

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Keywords

  • human factors and ergonomics
  • Industry 4.0
  • self-organizing manufacturing systems
  • e-learning in manufacturing
  • system and human reliability
  • digital manufacturing
  • automation safety
  • manufacturing systems usability
  • systems design
  • agile manufacturing
  • lean manufacturing
  • human–robot cooperation
  • visual inspection
  • cognitive ergonomics
  • personnel capacity planning
  • manufacturing processes
  • design of work systems
  • working environment
  • product and system safety
  • safety design issues

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Published Papers (7 papers)

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Research

19 pages, 3644 KiB  
Article
Semantic Kansei Engineering Approach for Game Controllers and Design Improvement
by A. G. González, O. López, M. M. Pizarro and J. F. Vázquez
Appl. Sci. 2024, 14(15), 6579; https://doi.org/10.3390/app14156579 - 27 Jul 2024
Viewed by 598
Abstract
The entertainment industry undergoes constant changes, and video games, along with the ways people enjoy them, evolve dynamically. In this context, there arises a need to innovate in areas such as user–game interaction and the design of conventional controllers to keep up with [...] Read more.
The entertainment industry undergoes constant changes, and video games, along with the ways people enjoy them, evolve dynamically. In this context, there arises a need to innovate in areas such as user–game interaction and the design of conventional controllers to keep up with these transformations. This study has found that the design requirements of the external geometry of video game controllers significantly impact users’ purchasing decisions, who often rely on their sensations and emotions. The primary aim of this research has been to demonstrate that it is possible to develop a specific methodology to establish design guidelines that evaluate geometry and ergonomic aspects, considering users’ emotional needs. To achieve this goal, the Kansei methodology has been employed, an engineering discipline that focuses on product design based on emotional interaction and user sensations when using them. Through advanced statistical techniques such as principal component analysis and linear regression, the set of observations has been reduced and a robust predictive model has been developed. Following this methodological approach, surveys and field studies have been conducted, thus differentiating the project from a conventional engineering approach in various stages. Special attention has been paid to the tactile part of the controller, especially its casing. After thorough analysis, the redesigned casing, incorporating improvements derived from statistical analyses, has been compared to existing market models. The results obtained show a significant improvement compared to existing market models, particularly highlighting enhancements in functional characteristics and ergonomic design, enabling comfortable use for individuals with different hand sizes and preventing the grip surface from being slippery. In summary, this work supports the effectiveness of the Kansei methodology as an approach to adapting product design to users’ perceptions and emotional needs. Full article
(This article belongs to the Special Issue Advances in Manufacturing Ergonomics)
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Figure 1

Figure 1
<p>Original video game controller.</p> Full article ">Figure 2
<p>Comparison of Nintendo, Xbox, and PlayStation surfaces.</p> Full article ">Figure 3
<p>Controller components.</p> Full article ">Figure 4
<p>Wiimote axis system.</p> Full article ">Figure 5
<p>Sony chronology.</p> Full article ">Figure 6
<p>Video game controllers surveyed.</p> Full article ">Figure 7
<p>Coordinates of video game controllers.</p> Full article ">Figure 8
<p>Sample survey for video game controller no. 1.</p> Full article ">Figure 9
<p>Correlation matrix of Kansei word pairs.</p> Full article ">Figure 10
<p>Observed (light-blue violins) and predicted (dark-blue violins) values of the Kansei pairs traditional-modern (upper chart) and ordinary-individualised (lower chart) for each video game controller. Black lines represent median values.</p> Full article ">Figure 11
<p>Values of observed (light-blue violins) and predicted (dark-blue violins) of Kansei pair ergonomic-procrustean for each video game controller. Black lines represent median values.</p> Full article ">Figure 12
<p>Resulting shapes.</p> Full article ">Figure 13
<p>Evolution of the original design to Design 1. The <math display="inline"><semantics> <msub> <mi>p</mi> <mrow> <mn>7</mn> <mi>x</mi> </mrow> </msub> </semantics></math> coordinate was MODIFIED from 0.0 mm to 0.1 mm.</p> Full article ">Figure 14
<p>Evolution of Design 1 to Design 2. The <math display="inline"><semantics> <msub> <mi>p</mi> <mrow> <mn>5</mn> <mi>y</mi> </mrow> </msub> </semantics></math> and <math display="inline"><semantics> <msub> <mi>p</mi> <mrow> <mn>6</mn> <mi>y</mi> </mrow> </msub> </semantics></math> coordinates were MODIFIED from 7.0 mm to 7.5 mm.</p> Full article ">Figure 15
<p>Evolution of Design 2 to Design 3. The <math display="inline"><semantics> <msub> <mi>p</mi> <mrow> <mn>4</mn> <mi>x</mi> </mrow> </msub> </semantics></math> coordinate was MODIFIED from 12.2 mm to 13.5 mm.</p> Full article ">Figure 16
<p>Evolution of Design 3 to Design 4. The <math display="inline"><semantics> <msub> <mi>p</mi> <mrow> <mn>3</mn> <mi>x</mi> </mrow> </msub> </semantics></math> coordinate was MODIFIED from 12.2 mm to 13 mm.</p> Full article ">Figure 17
<p>Evolution Design 4 to Design 5: The <math display="inline"><semantics> <msub> <mi>p</mi> <mrow> <mn>5</mn> <mi>y</mi> </mrow> </msub> </semantics></math> and <math display="inline"><semantics> <msub> <mi>p</mi> <mrow> <mn>6</mn> <mi>y</mi> </mrow> </msub> </semantics></math> coordinates were MODIFIED from 7.5 mm to 4.5 mm.</p> Full article ">Figure 18
<p>Evolution of Design 5 to Kansei redesigned video game controller. The product design phase included the following changes: greater rounding of the envelope and flattening of the lower peaks; no changes in the coordinates; and adjustments to the central layout.</p> Full article ">Figure 19
<p>Original game controller (<b>left</b>) vs. Kansei redesigned game controller (<b>right</b>).</p> Full article ">Figure 20
<p>Expanded view of control system with component table.</p> Full article ">
18 pages, 1135 KiB  
Article
Decision Support System for Mining Machinery Risk Mitigation Driven by Ergonomics and Contextual Theory
by Mirjana Misita, Aleksandar Brkić, Ivan Mihajlović, Goran Đurić, Nada Stanojević, Uglješa Bugarić and Vesna Spasojević Brkić
Appl. Sci. 2024, 14(15), 6413; https://doi.org/10.3390/app14156413 - 23 Jul 2024
Viewed by 563
Abstract
Despite being very old, the mining industry continues to be one of the major sources of pollution, with more people killed or injured than in all other industries. Prevention of incidents/accidents on machinery in mining pits and the issues of operator safety on [...] Read more.
Despite being very old, the mining industry continues to be one of the major sources of pollution, with more people killed or injured than in all other industries. Prevention of incidents/accidents on machinery in mining pits and the issues of operator safety on mining machinery largely depend on the ergonomic adaptation of the workplace, compliance with safety procedures and policies, and organizational and other influential factors. Evidently, scarce consideration of those factors in the available literature has not given satisfactory results till now. The aim of this paper is to first set up a comprehensive model based on ergonomic factors and contextual theory, which takes into account all the influencing factors on the occurrence of incidents/accidents and represents a complex system of interdependence of influential variables of diverse, mostly stochastic nature, and then design a software solution on the given basis. In this research, based on the extensive data collected, a model was generated using the structural equations modelling methodology, which was then used to design the reasoning logic in the expert system for mitigating the risks of the operation of mining machines. An innovative solution incorporating a mathematical model of the interdependence of influential variables into the stored knowledge base offers a decision support system that provides recommendations for the maintenance of a particular mining machine, depending on the assessment of model factors in a specific decision-making situation at the higher organizational level and ergonomic suitability for the operator at the lower organizational level, and, in that manner, enables the mitigating of risky/unwanted events. Full article
(This article belongs to the Special Issue Advances in Manufacturing Ergonomics)
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<p>A structural equation model that includes ergonomic and contextual factors affecting the risks of mining machinery.</p> Full article ">Figure 2
<p>User interface of the DSS for mitigating the risks of the operation of mining machines.</p> Full article ">
22 pages, 2093 KiB  
Article
Evaluating the Efficacy of a Passive Exoskeleton for Enhancing Ergonomics in Manufacturing
by Fatemeh Davoudi Kakhki, Armin Moghadam, Arnold Nieto and Hardik Vora
Appl. Sci. 2024, 14(13), 5810; https://doi.org/10.3390/app14135810 - 3 Jul 2024
Viewed by 960
Abstract
Manual material handling (MMH) significantly impacts worker health and productivity, often leading to musculoskeletal disorders (MSDs) primarily in the lower back. As a novel assistive technology, exoskeletons may serve as ergonomic tools to mitigate these work-related MSDs. It is essential to examine exoskeletons [...] Read more.
Manual material handling (MMH) significantly impacts worker health and productivity, often leading to musculoskeletal disorders (MSDs) primarily in the lower back. As a novel assistive technology, exoskeletons may serve as ergonomic tools to mitigate these work-related MSDs. It is essential to examine exoskeletons from the users’ perspectives before their widespread implementation in occupational settings. This study investigates the effectiveness of a passive back-support exoskeleton (BExo) in reducing perceived physical exertion and improving ergonomic safety in a manufacturing context. Twenty-two college students were recruited to perform MMH tasks in a controlled lab environment, both with and without the BExo, followed by completing a survey questionnaire on various aspects of the BExo. Using ANOVA, the study analyzed biomechanical exertion across various body parts and tasks. The findings indicate that the BExo substantially alleviated discomfort and physical exertion in the low back, shoulders and knees, thereby enhancing an ergonomic posture and reducing fatigue. These results underscore the potential of passive exoskeletons to boost workers’ safety and efficiency, providing valuable insights for future ergonomic strategies in industrial settings. Full article
(This article belongs to the Special Issue Advances in Manufacturing Ergonomics)
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Figure 1

Figure 1
<p>BExo used in the study; (<b>a</b>) back of the exoskeleton; (<b>b</b>) front of the exoskeleton.</p> Full article ">Figure 2
<p>Procedure setup and task performance in the lab; (<b>a</b>) front and back view of the BExo; (<b>b</b>) tasks completed by the participants.</p> Full article ">Figure 3
<p>Participants’ average PPE per support type.</p> Full article ">Figure 4
<p>Participants’ average sum of PPE with and without BExo per body part.</p> Full article ">Figure 5
<p>Effect of BExo support on PPE for different tasks.</p> Full article ">Figure 6
<p>Participants’ average sum of PPE per body part for lifting a box.</p> Full article ">Figure 7
<p>PPE per body part in relation to support for carrying a box.</p> Full article ">Figure 8
<p>Participants’ average sum of PPE per body part when walking with and without the exoskeleton.</p> Full article ">
13 pages, 3190 KiB  
Article
Critical Ergonomics and (Dis)Comfort Factors While Performing Tasks with Hand Tools on a Ladder: A Pilot Study
by Rosaria Califano, Antonio Auricchio, Mario Carbone, Lucio Dessì, Valentino Frasci, Angelo Landi and Alessandro Naddeo
Appl. Sci. 2024, 14(6), 2398; https://doi.org/10.3390/app14062398 - 12 Mar 2024
Viewed by 883
Abstract
Falls at height are among the major causes of fatal accidents at work, especially in the construction sector. Maintaining balance while performing a tool with both hands generates physical efforts and mental loading that needs to be managed for workers’ safety and health. [...] Read more.
Falls at height are among the major causes of fatal accidents at work, especially in the construction sector. Maintaining balance while performing a tool with both hands generates physical efforts and mental loading that needs to be managed for workers’ safety and health. The purpose of the study is to compare perceived (dis)comfort (overall and localized), the ergonomic risk, and the perceived effort through the acquired postures that subjects assumed during the execution of simple and common tasks both on a ladder and on the ground. 26 subjects were asked to perform four tasks in both conditions: top screwing, frontal screwing, object picking from the bottom forward, and object picking from the bottom sideways. Subjective and objective data were gathered for assessing subjective experience (discomfort and effort, perceived) and ergonomic risk. Results highlighted few ergonomic risk differences among “on ladder” and “on ground” tasks, while subjective data reveal significant differences in different scenarios. Furthermore, the knees and neck areas are the most critical ones. Full article
(This article belongs to the Special Issue Advances in Manufacturing Ergonomics)
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Figure 1
<p>Critical tasks: (<b>a</b>) Top screwing; (<b>b</b>) Frontal screwing; (<b>c</b>) Object picking from the bottom forward; (<b>d</b>) Object picking from the bottom sideways.</p> Full article ">Figure 2
<p>Camera positions: (<b>a</b>) Lateral; (<b>b</b>) Behind; (<b>c</b>) Above.</p> Full article ">Figure 3
<p>Localized Postural Discomfort Assessment. (1) chest; (2) arm (left and right); (3) forearm (left and right); (4) wrist (left and right); (5) pelvis; (6) thigh (left and right); (7) knee (left and right); (8) ankle (left and right); (9) neck; (10) shoulder (left and right); (11) back (dorsal area); (12) hip (left and right); (13) back (lumbar area); (14) buttock; (15) quadricep (left and right); (16) calf (left and right); (17) abdomen.</p> Full article ">Figure 4
<p>Example of Kinovea<sup>®</sup> angle measurement.</p> Full article ">Figure 5
<p>CAMan Software Interface. Comfort index for each body part and the whole body. Based on postural angles.</p> Full article ">
14 pages, 354 KiB  
Article
Lean Manufacturing Assessment: Dimensional Analysis with Hesitant Fuzzy Linguistic Term Sets
by William Alexander Chitiva-Enciso, Luis Asunción Pérez-Domínguez, Roberto Romero-López, David Luviano-Cruz, Iván Juan Carlos Pérez-Olguín and Luis Carlos Méndez-González
Appl. Sci. 2024, 14(4), 1475; https://doi.org/10.3390/app14041475 - 11 Feb 2024
Viewed by 1041
Abstract
Lean Manufacturing has become, in recent years, one of the most important philosophies for improving production and organizational systems. The literature shows that Hesitant Fuzzy Linguistic Terms Sets (HFLTSs) are highly capable of manipulating the uncertainty that the judgments made by evaluators carry [...] Read more.
Lean Manufacturing has become, in recent years, one of the most important philosophies for improving production and organizational systems. The literature shows that Hesitant Fuzzy Linguistic Terms Sets (HFLTSs) are highly capable of manipulating the uncertainty that the judgments made by evaluators carry and that they are subject to their perception, especially when used in combination with multicriteria decision making (MCDM) for the measurement of indicators in this type of system, as well as their general performance. However, it is still of interest to researchers to develop techniques and instruments that facilitate the measurement of the results obtained after applying this philosophy in organizations. This article proposes a model for the evaluation of the Lean Manufacturing performance through the Analytic Hierarchy Process (AHP) and Dimensional Analysis (DA) using HFLTSs. The results obtained show that the proposed model is a solid tool for the evaluation of Lean Manufacturing systems from a different perspective and that it can be integrated into the issuance of evaluations in a better way by considering human subjectivity. At the same time, it offers a strategy to create priorities in the action plans that Lean system managers propose after evaluating. However, it is important to apply the proposed model to multiple organizations and analyze the results obtained to maximize its benefits. Full article
(This article belongs to the Special Issue Advances in Manufacturing Ergonomics)
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<p>Flowchart of the algorithm to evaluate Lean Manufacturing by using HFLTS and DA.</p> Full article ">Figure 2
<p>Linear behavior of calculated iterations.</p> Full article ">
20 pages, 17073 KiB  
Article
An Ergonomic Study on the Operation Method and In-Vehicle Location of an Automotive Electronic Gearshift
by Sehee An, Jiwon Park, Hanul Kim, Hyemin Kang and Donghyun Beck
Appl. Sci. 2024, 14(2), 672; https://doi.org/10.3390/app14020672 - 12 Jan 2024
Viewed by 981
Abstract
This study conducted a survey to identify the best ergonomic operation method, in-vehicle location, and the effects of their combination on electronic gearshifts. A total of 15 different design alternatives were derived through combinations of three operation methods (lever slide, button push, and [...] Read more.
This study conducted a survey to identify the best ergonomic operation method, in-vehicle location, and the effects of their combination on electronic gearshifts. A total of 15 different design alternatives were derived through combinations of three operation methods (lever slide, button push, and dial rotation) and five in-vehicle locations (left wheel spoke, right wheel spoke, upper center fascia, lower center fascia, and center console). A total of 40 respondents with diverse ages and driving experiences evaluated the 15 different design alternatives across nine ergonomic evaluation measures (accuracy, efficiency, rapidity, learnability, intuitiveness, safety, preference, memorability, and satisfaction). The study results indicated that: (1) the lever slide and button push were superior to dial rotation for the operation method; (2) the lower center facia and center console were superior for the in-vehicle location, and (3) implementing the lever slide method in the center console location was found to lead to the best combination of the operation method and in-vehicle location, while implementing the button push method in the right wheel spoke or upper center fascia location also showed relative superiority. The study findings are expected to contribute to the ergonomic design of electronic gearshifts that can enhance the driver’s gear-shifting experience, thereby improving driving performance and safety. Full article
(This article belongs to the Special Issue Advances in Manufacturing Ergonomics)
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Figure 1

Figure 1
<p>Image used for the freehand design session.</p> Full article ">Figure 2
<p>The main effects of the operation method (mean {standard deviation} values of each operation method for each measure): (<b>a</b>) accuracy, (<b>b</b>) efficiency, (<b>c</b>) rapidity, (<b>d</b>) learnability, (<b>e</b>) intuitiveness, (<b>f</b>) safety, (<b>g</b>) preference, (<b>h</b>) memorability, and (<b>i</b>) satisfaction.</p> Full article ">Figure 3
<p>The main effects of the in-vehicle location (mean {standard deviation} values of each in-vehicle location for each measure): (<b>a</b>) accuracy, (<b>b</b>) efficiency, (<b>c</b>) rapidity, (<b>d</b>) learnability, (<b>e</b>) intuitiveness, (<b>f</b>) safety, (<b>g</b>) preference, (<b>h</b>) memorability, and (<b>i</b>) satisfaction.</p> Full article ">Figure 4
<p>The interaction effects between the operation method and in-vehicle location (mean {standard deviation} values of each design alternative for each measure): (<b>a</b>) accuracy, (<b>b</b>) efficiency, (<b>c</b>) rapidity, (<b>d</b>) learnability, (<b>e</b>) intuitiveness, (<b>f</b>) safety, (<b>g</b>) preference, (<b>h</b>) memorability, and (<b>i</b>) satisfaction. The blue, orange, and gray asterisks indicate significant in-vehicle location effects for the lever slide, button push, dial rotation methods, respectively, and the black asterisks indicate significant operation method effects for each in-vehicle location.</p> Full article ">
15 pages, 8394 KiB  
Article
Research on the Accuracy of Clothing Simulation Development: The Influence of Human Body Part Characteristics on Virtual Indicators
by Zhe Cheng, Xinzhou Wu and Victor Kuzmichev
Appl. Sci. 2023, 13(22), 12257; https://doi.org/10.3390/app132212257 - 13 Nov 2023
Cited by 1 | Viewed by 1011
Abstract
Currently, many virtual simulation design studies of compression pants do not consider pressure distribution and human body characteristics. Therefore, this study aimed to optimize the simulation design accuracy of compression pants by investigating female body characteristics to improve the pressure distribution and enhance [...] Read more.
Currently, many virtual simulation design studies of compression pants do not consider pressure distribution and human body characteristics. Therefore, this study aimed to optimize the simulation design accuracy of compression pants by investigating female body characteristics to improve the pressure distribution and enhance comfort. Firstly, we divided the body part features into flexible and rigid parts, performed compression relationship analysis between the material and the body, and collected qualitative and quantitative data related to the potential influencing factors. Subsequently, by conducting correlation analysis of the data, a pressure prediction model was established to address the pressure value errors in the simulation data. The research results showed that there was a significant difference between the real and virtual pressures in the flexible parts of the female body, and that the real pressure was closely related to the elasticity and thickness properties of the material. By optimizing virtual pressure values, the consistency between the virtual pressure and real test results can be significantly improved. The accurate prediction and optimization of pressure values can lead to the reduction of material waste and energy consumption during the manufacturing process. Full article
(This article belongs to the Special Issue Advances in Manufacturing Ergonomics)
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<p>Research flowchart.</p> Full article ">Figure 2
<p>Test location and points.</p> Full article ">Figure 3
<p>Comparison of PV and PR data of five materials: (<b>a</b>–<b>e</b>) pressure of M1, M2, M3, M4, and M5; (<b>f</b>) average difference.</p> Full article ">Figure 4
<p>Correlation between pressure under different stretching conditions and KES data.</p> Full article ">Figure 5
<p>Correlation between average pressure and KES data.</p> Full article ">Figure 6
<p>The PR measurement and prediction values based on the mechanical properties of the material: (<b>a</b>) PR<sub>hip</sub> (E = 15%) calculated based on variable LT; (<b>b</b>) PR<sub>hip</sub> (E = 10%) calculated based on variable T0; (<b>c</b>) PR<sub>waist</sub> (E = 10%) calculated based on variable T0; (<b>d</b>) PR<sub>thigh</sub> (E = 5%) calculated based on variable HG5; (<b>e</b>) PR<sub>mid-thigh</sub> (E = 5%) calculated based on variable HG5; (<b>f</b>) PR<sub>calf</sub> (E = 5%) calculated based on variable G.</p> Full article ">Figure 7
<p>Pattern blocks of compression pants.</p> Full article ">Figure 8
<p>Compression pant models with pressure maps.</p> Full article ">Figure 9
<p>Compare the prediction with test results of compression pants.</p> Full article ">
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