Handling Operations Research Articles

Ergonomic Risk Assessment for Manual Handling Activities in Automotive Workshop

Ergonomic risk assessment tools are tools that have been designed to solve the problem of ergonomics in the workplace from manual material handling activities. The objective of this study is to investigate Musculoskeletal Discomfort among workers related to manual handling activities using Cornell Musculoskeletal Discomfort Questionnaires (CMDQ); to assess an ergonomics risk factor among workers related to manual handling activities using Manual Handling Assessment Chart (MAC), NIOSH Lifting Equation(NLE), and Key Indicator Method for Manual Handling Operation (KIM-MHO) method and; to compare the results between CMDQ and assessment tools. This case study was conducted in Parit Raja, Johor, Malaysia involving 34 male mechanics workers. The tools used are as stated in the objective with the help of measurement tools such as a goniometer. The result of the CMDQ reveals that the body part with the highest discomfort level among the workers in the lower back, shoulder right and shoulder left with the percentage from the total discomfort score of 20.91%, 13.57%, and 13.36% respectively. From the result of the assessments, it is concluded that the highest risk factor contributing to the MSDs is the bad posture of the worker during the manual handling operation followed by the frequency of lifting and the weight of the load. By comparing assessment tools, the first comparison is made between the CMDQ versus KIM-MHO, MAC Tools and NLE. In this comparison that, it is highlighted the result type from CMDQ are different from the KIM-MHO, MAC Tools and NLE as its questionnaire result shows us the discomforts levels on the body of workers and the body parts affected on their body for the last seven days but the assessment tools results show us the risk factor that contributes to the MSDs. For the comparison between the three assessment tools, it can be said that the tools that have the highest correlation with CMDQ are MAC Tools. In conclusion, most workers suffer from MSDs in their lower back due to their bad posture during manual handling. KIM-MHO is the best assessment tool among the three as it has the highest significance value while being the easiest tool to be used.

Enhancing Situational Awareness for Remote Control of Ship Cranes

Abstract Cargo handling in ship operations poses risks due to heavy loads, necessitating innovation to mitigate accidents. Automation and remote control offers safer and more efficient operations by moving people from hazardous situations. Smaller and remote ports often rely on geared ships, which are typically manually operated. A first step towards automation is to remotely control these cranes. In remote control, the operator needs to gain situational awareness through sensor inputs. Previous research has shown that there is a need to investigate the sensor configuration and placement to provide situational awareness, particularly considering the placement of cargo onboard. This study seeks to identify needed sensor configurations for situational awareness in remote control of ship cranes using a simulator framework. A modular crane simulator framework has been developed to evaluate situational awareness for different sensor configurations. The sensor configuration has been evaluated with feedback from a crane expert. This research has identified potential sensor configurations for enhancing situational awareness in remote crane operations. The developed simulator framework has demonstrated its flexibility and efficiency as a platform for testing and optimizing cargo handling operations.

Mathematical modeling and optimizing of yard layout in automated container terminals

The yard layout significantly influences the performance of automated container terminals (ACTs), especially those employing a perpendicular stack configuration, where the yard blocks are perpendicular to the quay line. Thus, this study is dedicated to optimizing the yard layout tailored for ACTs with such configurations. First, we develop cycle time formulas for the automated stacking crane (ASC) by considering the dependency between its successive handling operations, highlighting the impact of the previous operation on the subsequent one. Further, to address the interferences between the two ASCs within a yard block, a novel hybrid simulation-analytical approach is proposed. Then, utilizing the derived ASC cycle time formulas, an analytic model is constructed based on the G1/G/1 queuing theory to optimize the yard layout design parameters (including the number of yard blocks, bays per block, and rows and tiers per bay) from the perspective of both cost-effectiveness and operational efficiency. In the numerical experiments, optimal yard layouts for two ACTs of different sizes are generated by utilizing the analytic model, and design insights are derived through the sensitivity analysis. The experiments underscore the importance of considering the dependency between successive handling operations and ASC interferences in the design of yard layouts for ACTs.

A hybrid SgDT framework for risk analysis of container-handling operations at automated container terminals

With the booming maritime economy and the steady expansion of port production, automated container terminals (ACTs) have rapidly developed worldwide. The safety and stability of container-handling operations at ACTs are crucial for maintaining high efficiency and performance in maritime transportation and global supply chains. However, few studies have focused on the quantitative risk analysis of container-handling operations at ACTs. This study proposes a hybrid SgDT (STPA-grey-DEMATEL-TAISM) approach to analyze risk factors and their coupling interrelationships within ACT handling operations. Initially, 22 factors influencing ACT handling operations were identified based on the system theoretic process analysis (STPA) model and literature. Subsequently, grey theory and decision-making test and evaluation laboratory (DEMATEL) were fused to visualize the cause-effect relationships of these factors. Finally, the total adversarial interpretive structural model (TAISM) was adopted to extract the hierarchical interrelationships among these factors using an adversarial hierarchical structure. The findings showed that poor supervision, communication network failures, sensor malfunctions, equipment malfunctions, lack of safety awareness, and interruptions of the power supply are the most critical factors influencing ACT handling operations. This study provides theoretical insights and practical implications for managers to enhance ACT handling risk management.

Electric Taxiing System. Kinetic Energy Recovery System as an Electric Taxiing Solution: Economic and environmental analysis: Phenom 300 case study

The aviation industry has thrived in recent years, with a significant increase in passenger numbers, leading to the development of larger aircraft fleets and the expansion of airport infrastructure. In 2019, more than 4.5 billion passengers traveled by airplane, which represents an 80% increase compared to 2009. As a consequence, this growth has also resulted in longer taxiing times for aircraft, increasing fuel consumption and operational costs. The industry's CO2 emissions have quadrupled since the 1960s, with over 1 billion tons released in 2019, contributing to global warming. Given that the improvements being made to current propulsion systems and the production of over 600 million liters of SAF (Sustainable Aviation Fuel) in 2023 do not seem sufficient to meet the ambitious goals set by regulators and operators, the logical solution would be to develop a system capable of moving the aircraft on the ground using alternative, cleaner, and cheaper energies, such as electric power. This paper explores the latest advancements in electric propulsion systems, specifically focusing on external and onboard systems. After the state of the art is established, this paper will cover a case study and propose a new alternative for an onboard system called ETS – Electric Taxiing System. The ETS is a 100% electric system for ground handling operations designed to use only the kinetic energy stored in a battery pack, which is recovered during aircraft landing and braking events. Although there are some studies on this topic, the author considers this paper to be more comprehensive as the results computed here take into account 96 variables, 60 simulations, several flight plans, and real-world data. The case study focuses on the implementation and dimensioning of the ETS, considering electric motor power and torque, and battery capacity for the Embraer Phenom 300. A brief economic and environmental analysis was also conducted, considering the operation of NetJets Europe, the world's leading and largest private jet company.

Symmetry-Enhanced LSTM-Based Recurrent Neural Network for Oscillation Minimization of Overhead Crane Systems during Material Transportation

This paper introduces a novel methodology for mitigating undesired oscillations in overhead crane systems used in material handling operations in the industry by leveraging Long Short-Term Memory (LSTM)-based Recurrent Neural Networks (RNNs). Oscillations during material transportation, particularly at the end location, pose safety risks and prolong carrying times. The methodology involves collecting sensor data from an overhead crane system, preprocessing the data, training an LSTM-based RNN model that incorporates symmetrical features, and integrating the model into a control algorithm. The control algorithm utilizes swing angle predictions from the symmetry-enhanced LSTM-based RNN model to dynamically adjust crane motion in real time, minimizing oscillations. Symmetry in this framework refers to the balanced and consistent handling of oscillatory data, ensuring that the model can generalize better across different scenarios and load conditions. The LSTM-based RNN model accurately predicts swing angles, enabling proactive control actions to be taken. Experimental validation demonstrates the effectiveness of the proposed approach, achieving an accuracy of approximately 98.6% in swing angle prediction. This innovative approach holds promise for transforming material transportation processes in industrial settings, enhancing operational safety, and optimizing efficiency.

Optimizing the Allocation of Quay Cranes and Prime Movers for Container Handling Operations

Optimizing the Allocation of Quay Cranes and Prime Movers for Container Handling Operations

Integrated optimization of berth allocation problem with berth shifting strategies and ballast water management for dry bulk ports

In maritime operations, ballast water operations and cargo handling operations are carried out simultaneously to determine the operational efficiency of vessels in port. However, the ballast water pumping rate lags behind the growing efficiency of bulk cargo handling, resulting in operational interruptions and extended stay times at ports. To address this challenge, this paper introduces a novel ballast water management strategy: vessels first handle a portion of their cargo and then shift to a lay-by berth for mid-pumping. This strategy results in multiple shifting movements of vessels within the berth allocation plan. Therefore, to better implement this strategy, we develop an integrated model of berth allocation and ballast water pumping management, with the special considerations of multi-berth shifting strategies and ballast water weight. To efficiently solve this model, we present a hybrid heuristic algorithm based on adaptive genetic algorithms and the critical path method. The computer experiments reveal that the mid-pumping strategy effectively circumvents untimely pumping, shortens the vessel port stay time, and yields a 9.42% reduction in the total stay time. This research further elucidates managerial insights to inform and enhance port operations.

Development and validation of a rapid and simple HILIC-MS/MS method for the determination of biogenic amines in tuna fish

The production of biogenic amines (BAs), which are markers of both quality and safety in fish and fishery products, is influenced by the harvesting technique, handling, and other operations including those carried out on board the vessel. Scombroid dark-meat fish (e.g. tuna) are the fish species most frequently linked to histamine poisoning. The most commonly found BAs in fish are histamine, tyramine, putrescine, and cadaverine, which are produced when microbes decarboxylate the corresponding free amino acids. In this study, a rapid and cost-effective HILIC-MS/MS method was developed and validated for the determination of putrescine, cadaverine, histamine and tyramine in tuna samples. A simple sample preparation procedure was followed using the solvent mixture MeOH/H2O (50/50, v/v), 0.1 % acetic acid for protein precipitation and analyte extraction. Intra- and inter-day accuracy, expressed as %Recovery (%R), ranged from 88.0 % (Cad) to 102.7 % (Tyr) and from 85.0 % (Cad) to 99.8 % (Tyr), respectively. Intra- and inter-day precision, expressed as %Relative Standard Deviation (%RSD), ranged from 0.4 % (Tyr, Put) to 3.3 % (His) and from 0.7 % (Tyr) to 5.0 % (Cad), respectively. Limits of detection (LOD) and quantification (LOQ) varied from 0.0009 to 0.0940 mg/kg and from 0.0030 mg/kg to 0.3100 mg/kg, respectively, depending on the analyte. Regarding the potential toxic effects linked to biogenic amines in foods, samples examined in this study showed no risk. The proposed method is an important analytical tool for routine analysis of BAs in fish products.

An Intelligent Human–Machine Interface Architecture for Long-Term Remote Robot Handling in Fusion Reactor Environments

This paper addresses the intricate challenge posed by remote handling (RH) operations in facilities with operational lifespans surpassing 30 years. The extended RH task horizon necessitates a forward-looking strategy to accommodate the continuous evolution of RH equipment. Confronted with diverse and evolving hardware interfaces, a critical requirement emerges for a flexible and adaptive software architecture based on changing situations and past experiences. The paper explores the inherent challenges associated with sustaining and upgrading RH equipment within an extended operational context. In response to this challenge, a groundbreaking, flexible, and maintainable human–machine interface (HMI) architecture named MAMIC is designed, guaranteeing seamless integration with a diverse range of RH equipment developed over the years. Embracing a modular and extensible design, the MAMIC architecture facilitates the effortless incorporation of new equipment without compromising system integrity. Moreover, by adopting this approach, nuclear facilities can proactively steer the evolution of RH equipment, guaranteeing sustained performance and compliance throughout the extended operational lifecycle. The proposed adaptive architecture provides a scalable and future-proof solution, addressing the dynamic landscape of remote handling technology for decades.

Cold plasma treatment: An innovative approach to reduce the moisture and the water reabsorption in iron ore concentrate

Wet beneficiation is a primary process employed by mining companies for iron ore concentration. The moisture content in the ore is a result of this beneficiation process, in addition to inherent moisture within the mineral composition. The moisture content of iron ore is a crucial parameter that requires effective control to ensure safe handling and transportation operations. Surface plasma treatment of iron ore has been investigated as a method to enhance the hydrophobicity of ore particles, thereby reducing residual moisture and water reabsorption by the particles. The samples underwent treatment using argon plasma and cold hexamethyldisiloxane (HMDSO) plasma, leading to the formation of a thin, silicon-rich surface layer. The treatments were applied to both polished ore samples and fine powder samples. The plasma treatment resulted in a reduction in moisture content and water absorption. The reabsorption of water decreased to approximately 35% of the pretreatment values. Contact angle measurements demonstrated that all HMDSO-treated samples exhibited hydrophobic behavior, with contact angles ranging from 110° to 120°, while the untreated samples exhibited angles close to 0°. Furthermore, atomic force microscopy (AFM) topographic imaging revealed a granular structure in the thin films.

Design and development of a not actively driven modular device for parts feeding and sorting

The current paper focuses on developing and designing a not actively driven module for material handling operations in the field of intra-logistic. This device, belonging to the class of systems known as smart surfaces, is planned to be assembled with others to create manipulative arrays. As a novel feature, the reported concept aims to generate the frictional forces required for surface operation avoiding motors and with a simplified design. The article not only presents the design of the concept, but also the analytic models used to describe its operation and handling forces. In addition, a characterization of the fundamental parameters and the validation of the mentioned analytic descriptions together with the functioning itself are reported. As result, the analysis and the measurements presented show a real solution for a not actively driven concept, along with a methodology to characterize it and predict its handling capabilities. Specifically, the validation test proved that the model is able to represent the behavior of the friction forces with relative errors mainly in the range of 10% or lower.

Novel odor sensing intelligence and surveillance capabilities in controller-responder robots

The rise in global travel has led to an increased need for heightened security measures at airports. Despite the best efforts of airport security officers, in the past year, hundreds of kilograms of illegal drugs and thousands of agricultural invasive species have found their way into the country, posing a severe threat to public safety and the environment. Moreover, human threats pose a significant risk to civil aviation, reinforcing the need for advanced security technology. In response to these challenges, NOSI (Novel Odor Sensing Intelligence) and ROSI (Reconnaissance Operations Security Intelligence), intelligence surveillance systems consisting of semi-autonomous controller-responder robots, were developed as a proof of concept to supplement the efforts of security and K-9 (police dogs) operators at airports. NOSI is equipped with multi-channel gas sensors for odor detection, enabling it to identify illegal drugs and invasive species in the baggage handling process, while ROSI is equipped with computer vision to identify individuals already in the government’s database of persons of interest. These coordinated robots also provide travelers with important information pertaining to their journey and allow them to trigger emergency alerts. The robots were tested in a custom-designed test bed that replicated both the behind-the-scenes baggage handling and front-office customer service operations of an airport, thus simulating a realistic airport-like setting. Based on design criteria, NOSI and ROSI demonstrated success rates of 73.4 percent and 69.8 percent, respectively. Improvements in areas of robot stability, sensor accuracy, and feature expansion were documented for further development. In conclusion, the NOSI and ROSI framework can enhance the efficiency and accuracy of airport infrastructure monitoring and supplement the capabilities of human and K9 operators. Overall, this approach can potentially revolutionize operations in various infrastructures and represents the future of human-robot collaboration.

Formation of Professional Competence in Future Border Guard Officers of Canine Units at a Military Educational Institution

Purpose: This article delves into the formation of professional competence in future border guard officers of canine units at a military educational institution, focusing on the training programs and methodologies aimed at preparing these officers for effective work with canine units. Methods: The study examines the specialized training programs and methodologies utilized to equip future officers with essential skills in dog handling, scent detection, search and rescue operations, obedience training, and tactical deployment. It emphasizes the significance of developing competence in these areas to enhance border control operations involving canines. Results and discussion: By analyzing the specific training approaches of military educational institutions, this study sheds light on the methods employed in preparing future border guard officers, underscoring the necessity of a comprehensive and specialized training regimen for optimal performance in canine unit operations. Implications of the research: The findings of this study contribute to refining training practices and fostering the development of competent canine unit officers within the military framework, thereby enhancing the efficiency and effectiveness of border control operations. Originality/value: This research adds value by offering insights into the tailored training methodologies essential for nurturing professional competence in future border guard officers of canine units, highlighting the critical role of specialized knowledge and skills in ensuring successful canine-assisted operations in border security.

Concept of operation of the Agile Robot Transporter for ITER in-vessel maintenance

ITER machine availability is crucial for fusion reactors in order to be the main source of electricity, which is affected by many aspects. This paper focuses on maintenance aspects of the machine. As the plasma facing components inside the fusion reactors become highly activated caused by the neutrons generated by fusion reactions, maintenance of the fusion reactors needs to be done by remote means. In order to increase machine availability, it is required to have efficient maintenance scenario in terms of time and effort, which can be achieved through effective in-vessel remote handling (RH) operations, simplified maintenance of the RH system itself, well-coordinated logistics, and trained personnel, etc. All these aspects need to be investigated during the design phases, which requires a well-defined concept of operation of the RH systems. This paper describes the concept of operation of the Agile Robot Transporter (ART), an ITER in-vessel RH system, that is under development to carry out neutron and optical diagnostic calibrations, and removal/replacement of the blanket first wall samples. Based on the functional analysis of the required in-vessel tasks, system requirements are defined. Among them, key requirements to improve RH operation efficiency are identified and the ART is designed accordingly. Efficient deployment and removal operations of the ART are crucial so that it requires less vacuum vessel (VV) port opening and less cask transportation, which reduces needs for hands-on operations resulting in less human radiation exposure. Various and flexible tool exchange and storage concepts are proposed that allow parallel operations between the in-vessel and ex-vessel RH systems. Modular and re-configurable design is proposed for easy RH system maintenance, and effective rescue operations to rescue the RH system when it fails.

Abstract 2063: Using the edge wells in 96-well plates without increasing variability in cytotoxicity assays through thermal controls

Abstract There are very few things as fundamental to cancer research as the 96-well-plate, yet edge effect has continued to cause problems since its introduction. The most common remedy for edge effect is to avoid using edge wells altogether, which eliminates 37% of the plate from the assay. If all of those wells could be used, an estimated USD $119M could be saved in research costs annually across the globe. We have shown previously that maintaining constant thermal control of plating conditions reduces variability in stem cell toxicity assays. Here, we ask the question: can we use the edge wells in cancer screening assays if we control thermal changes that happen in the traditional lab as cells are plated at room temperature and incubated at 37 degrees C? We had the null hypothesis that including the edge wells would add variability to an A549 cytotoxicity assay, even if the cell handling and incubation temperatures were matched and held constant. We plated A549 cells at either room temperature (like a BSC) or at 37 degrees C using the Xvivo System, which maintains constant temperature, oxygen, CO2, and relative humidity levels around cell handling operations. The cells were treated with serial dilutions of peracetic acid/hydrogen peroxide solution. After incubation for 3 days, the plates were stained with Crystal Violet and assessed for cell density (n=3 separate experiments). The null hypothesis was disproven. We found that if the plates were maintained at 37 degrees C during cell handling as well as incubation, that cell distribution was random and even across all wells, even edge wells. We found that there was no statistical difference between edge well and center well results in cytotoxicity assays. Edge wells were usable without increasing variability in the assays. This is consistent with earlier findings showing that when temperature changes between cell plating and incubation were averted, stem cell distribution across the plate was random and the edge effect was eliminated. Citation Format: Alicia D. Henn, Shannon Darou, Randy Yerden. Using the edge wells in 96-well plates without increasing variability in cytotoxicity assays through thermal controls [abstract]. In: Proceedings of the American Association for Cancer Research Annual Meeting 2024; Part 1 (Regular Abstracts); 2024 Apr 5-10; San Diego, CA. Philadelphia (PA): AACR; Cancer Res 2024;84(6_Suppl):Abstract nr 2063.

Hexad robot: A 6-dof parallel PnP robot to accommodate antagonistic rotational capability and structural complexity

This paper proposed a new structure of full-mobility parallel robot, which combined the advantages of high-rotational capabilities and structural simplification, for high-speed operations of material handling. The proposed robot structure integrates lightweight and simple linkages with a relatively complex (i.e., compared to the single platform with limited rotational capability) articulated mechanism or gear train as wrist mechanism to amplify the end-effector rotations, but without significantly increased structural complexity of gearbox, compared to the existing designs. Parametric modeling are carried out for position analysis, workspace evaluation, singularity identification and dynamic characterization to qualify the proposed robot. Moreover, the structure of the proximal links are designed with topology optimization to ensure design requirements of stiffness and low inertia. The performance evaluation shows that the proposed robot can be of high potential application in the industrial production line.

Ranking of Technologies for Intralogistic Bulk Material Handling Processes Using Fuzzy Step-Wise Weight Assessment Ratio Analysis and Axial-Distance-Based Aggregated Measurement Methods

The logistics network is considered the provider of logistics activities in supply chains. The fluctuating requirements of customers and the logistics network’s complex structure are only a few of the factors that cause challenges to its management. Industrial facilities are particularly vulnerable to challenges because material handling operations dominate in addition to manufacturing activities. Disruptions at industrial plants are disseminated through the logistics network, affecting all supply chain participants. As a result, reducing material handling time and costs to decrease material losses, pollution, and productivity is vital to their business. Due to their distinctive properties and significant share in finished goods, bulk materials are particularly vulnerable to issues during manufacturing. Accordingly, this study aims to rank and select technologies for handling bulk materials in an industrial plant where the production of construction materials is performed. This paper proposes four alternative solutions for the observed case study, and nine criteria were selected for the evaluation. A new hybrid multi-criteria decision-making model is proposed. The model combines Fuzzy Step-Wise Weight Assessment Ratio Analysis (SWARA), used to determine the weight of criteria, and the Axial-Distance-Based Aggregated Measurement (ADAM) method, used to rank alternative solutions. The model results indicate that the pneumatic conveyor is the best ranked alternative that significantly increases productivity, reduces losses, and improves working conditions. The key contributions of this study are its analysis of the efficiency of the technologies proposed for bulk material handling and the development and implementation of a model framework for the ranking of these technologies.

Use of Augmented Reality as a Tool to Support Cargo Handling Operations at the CARGO Air Terminal.

(1) Background: A current trend observed in the logistics sector is the use of Industry 4.0 tools to improve and enhance the efficiency of cargo handling processes. One of the popular solutions is an augmented reality system that supports operators in everyday tasks. The article aims to present design assumptions for implementing an augmented reality system to support air cargo handling at the warehouse. (2) Methods: Research was carried out based on a five-stage analytical procedure, aiming to analyze the current state and identify the potential for implementing the AR system. The following methods were used to collect data: co-participant observations, process analysis, direct interviews, analysis of internal documentation, and applicable legal regulations. (3) Results: The conducted research allowed for identifying information flows accompanying cargo flows and developing a project to automate selected information flows. The obtained results made it possible to identify operations for which the AR system's implementation will increase their effectiveness and efficiency. (4) Conclusions: The obtained results identified the need to develop a hybrid algorithm for arranging cargo in the warehouse and to build a system supporting self-verification of markings on air cargo.

Smart Currency Counter Machine

This project presents the development of a cost-effective and efficient Smart Currency Counter Machine utilizing the Arduino Uno microcontroller for the specific purpose of accurately counting 50- and 20-Rupees notes. In an era where currency counting accuracy is of paramount importance, this system offers a reliable solution for businesses and individuals.[1] The machine employs a combination of image processing techniques and sophisticated sensors to distinguish between various currency denominations, specifically the 50- and 20-Rupees notes.[3] The Arduino Uno's computational capabilities and versatility make it an ideal choice for controlling the system, while the use of open-source libraries and affordable components ensures accessibility to a wider range of users. Preliminary testing demonstrates that the Smart Currency Counter Machine provides fast, accurate, and user-friendly currency counting, contributing to improved financial record-keeping and efficiency in cash handling operations.[4]