Fuzzy Ergonomic Expert System for Assembly Line Design Problem

Abstract

In the era of Industry 5.0, prioritizing ergonomics in manufacturing systems is crucial. Assembly Line Balancing Problems (ALBPs) are integral to efficient manufacturing, optimizing lines to eliminate bottlenecks and enhance productivity. Recent developments emphasize Ergonomic ALBPs (Ergo-ALBPs) and the integration of Human Factors and Ergonomics (HFE) to address ergonomic risks. A research gap exists in applying ergonomic considerations in the design phase known as Ergo-ALDPs as corrective ergonomic interventions cost significantly more than preventive measures taken during the design phase. This study presents a novel approach, the fuzzy Ergo-ALDP, which extends the Ergo-ALBP to handle imprecise task times and ergonomic risks in the design phase.It introduces a fuzzy ergonomic expert system, utilizing fuzzy logic and Digital Human Modeling (DHM) to simulate worker interactions in assembly line optimization. The proposed fuzzy Ergo-ALDP addresses this gap with a constructive heuristic integrated with fuzzy logic, emphasizing feasibility. Our research introduces a unique fuzzy ergonomic assessment method to evaluate task, workstation, and assembly line ergonomics using an expert system. We validate this approach using one synthesized numerical instance. This research contributes to assembly line optimization, aligning with Industry 5.0's human-centric vision. The comprehensive fuzzy ergonomic assessment model bridges gaps and optimizes ALDPs under uncertainty, promising improvements in productivity, worker satisfaction, and operational efficiency. By addressing the intersection of ergonomics, uncertainty, and assembly line optimization, this paper significantly contributes to advancing the field and promoting a safer and more efficient manufacturing environment.