با استفاده از نرم افزار ارگونومیک در فرایندهای تولیدی غیر تکراری: یک مطالعه موردی

Thanks to simulation software, ergonomic analysis has ceased being the complex and time-consuming task that it once was. However, the majority of Small and Medium Enterprises (SMEs) are still unaware of these tools. This paper uncovers, by means of a case study based on a real process, the advantages and the practical barriers involved in the implementation of 3D simulation tools in SMEs. The chosen case study is based on a non-repetitive manufacturing process, the most common within this size of companies. Relevance to industry Modeling and simulation tools could help to improve ergonomics in Small and Medium Enterprises. Many companies deal with non-repetitive manufacturing processes that could be hazardous for employees.

Any decision-making process significantly benefits from the use of information systems. Developments in computer science have allowed ergonomic applications that were once limited to large computers to now be set up in personal computers, drastically broadening their access and availability. However, many businesses have not taken full advantage of these information systems. They have generally downplayed the importance of ergonomics simulation packages and, as a consequence, this type of application has yet to become widely implemented. To make matters worse, the cost of software licensing is still high compared to other business applications. This situation is most evident in Small and Medium Enterprises (SMEs), the majority of which do not even have a department dedicated to the ergonomic study of the workspace. However, the risk of ergonomic problems is the same for all companies, regardless of their size. In order to analyze the possible uses of these ergonomic tools in SMEs, a practical case study was developed using a commercial tool, simulating a real working process in a company. Another objective of the project was to analyze the potential of these tools in a non-repetitive manufacturing process, that is, in a process where the working cycle is not fixed and the processed parts are not identical.

The commercial applications dedicated to the ergonomic study of working positions include the most well-known ergonomics studies (OWAS, Lift Analysis) and also include the standard time establishment by means of predetermined MTM times. Furthermore, the software allows for the changing of a worker's personal characteristics (gender, height, weight, etc.) so the simulation can be adapted to a range of workplace scenarios. Most studies that use simulation tools based on mannequins are focused on the analysis of repetitive hazardous postures or on the ergonomic design of products or processes. In those cases, the company (even if the company is an SME) can benefit from the use of these simulation tools. In fact, it is not necessary to use sophisticated tools and, along with traditional CAD tools, elements of the DHM may be used as well. Besides, the use of simulation not only improves current processes but also allows for the testing of new processes before they are implemented. By using the standard tools included in the software, it is possible to have a virtual representation of the future workstation. This is one of the aspects, which make simulation stand out from traditional methods of analysis. However, this paper represents the case of an SME with non-repetitive production. In these companies, the products are not always identical and are not placed in the same location of the workplace (or in a matrix of possible locations). Besides, the working cycle of each product is different. In those cases, problems in ergonomics and productivity are similar to companies with repetitive production, but the modeling process is more laborious because the model is different for each product cycle.