Evaluating Worker Interactions in U-Shaped Production Lines Using Functional Resonance Analysis Method

Abstract

The need for resilient production to cope with the variation in workers’ performances has been increasing due to the employed population's decline and the workers’ aging in developed countries. U-shaped production lines have attracted attention as a possible solution to this problem because of their high flexibility and capability to deal with external environmental factors by promoting workers’ interactions. However, more than conventional methods are required to analyze workers’ interactions in U-shaped production lines because of the high complexity and flexibility. This paper proposes a novel framework based on the functional resonance analysis method (FRAM) for investigating the effect of worker interactions in a U-shaped production line. The framework introduced two supportive methods, i.e., the algorithmic analysis and KOMPASS evaluation criteria, to objectively conduct the FRAM analysis process. The feasibility of the framework was explored by a case study focusing on a highly skilled worker in a motor winding process. The results showed that the adjustment feature of the worker based on the interaction factor represented by the FRAM models played a critical role in resilient production. The proposed framework provides a systematic procedure to investigate interactions among multiple workers in U-shaped production lines for resilient production.