Integrated lean and ergonomic assessment for the planning of human-centered factories

Abstract

This research proposes an approach for evaluating human-centered work processes by combining Value Stream Mapping and ergonomic assessment of physical workload. Value Stream Mapping is a method used to create a visual representation of the flow of materials and information required to deliver a product, and aids in identifying potential bottlenecks and other constraints. However, it does not consider the effect of physical ergonomics on process execution and planning. To bridge this gap, the Ergonomic Assessment Worksheet screening tool is used to gain insight into unfavourable physical workload situations. The proposed approach follows five main steps: (i) scope definition, (ii) Value Stream Map, (iii) time study, (iv) ergonomic assessment, (v) combined analysis. A case study is conducted at a bicycle manufacturer to demonstrate the effectiveness of the approach in quantifying the impact of physical ergonomics on process performance. The method enables a systematic analysis of process chains to identify critical steps from both lean and ergonomic perspectives, emphasizing the importance of worker's physical well-being and the ability of ergonomic assessment methods to enhance Value Stream Maps.