Some aspects of ergonomics in assembly planning

Abstract

The recognition that there are not only humane but also economic reasons for improving work conditions for serial assembly workers is reflected in a new engine assembly system at Mercedes Benz AG. This system was planned by Mercedes Benz AG in collaboration with the Fraunhofer-Institute for Industrial for Industrial Engineering, Stuttgart. This new assembly system offers the following advantages: • planning with ergonomic-oriented planning techniques (e.g., videosomatography, personnel-oriented simulation) • individually adjustable height at every workstation • individual direction of entrance at every workstation • individual information system with terminals at every workstation The purpose of this article is to describe the ergonomic advantages of the assembly system, the individual planning steps it involves, and finally, the actual realization of the system. Relevance to industry Until today, the experiences with the assembly system, which has been in operation since 1992, has been positive: the new options, for example, the adjustable height, the information system, or the flexible work contents have met with acceptance among the workers and are utilized by them. If we compare some of the characteristic values for this assembly system with the conventional assembly line systems still in use, we find that this new assembly system • has the lowest rework rate • inspires the most suggestions for improvement • has lower absenteeism • causes only minimal time loss (by reducing compensation time).