The fourth industrial revolution, or Industry 4.0 paradigm, gives scope to resolve the challenges of 21st-century manufacturing. Physical stress or worker’s work-related musculoskeletal disorders (WMSDs) remain a challenge to the manual assembly line production system. This research provides a new intelligent framework to recognize and facilitate an assembly line fatigue worker. The intelligent framework provides a real-time fatigue status of each assembly worker on the manager’s work screen. Furthermore, the intelligent system provides a suitable solution to facilitate the fatigue worker, without disturbing the line balance. A novel approach is given to recognize the assembly line workers’ physical stress or work fatigue using the Knowledge-based Intelligent System (KBIS) methodology. Similarly, intelligent work rotation algorithms are proposed to find the solutions to facilitate the fatigue worker. Details of intelligent fatigue recognition, making of a learning-based fatigue recognition model, Industrial Internet of Things (IIoT) setup for worker’s real-time status monitoring, and Pseudocodes of intelligent work rotation algorithms are discussed in detail. Furthermore, an illustrative example is given to demonstrate the scope of the proposed framework for a manual assembly line system. Four worker assembly line is considered during the illustration. Details of intelligent fatigue worker recognition with their current-status is explained. The intelligent algorithm has recognised that the worker 4 is under fatigue condition. Furthermore, the intelligent facilitation algorithm found the worker 6 as alternative worker to facilitate the fatigue worker. Learning-based classification models are used to make fatigue recognition model. However, Random Forest model has shown better performance in terms of prediction accuracy while recognising the worker’s fatigue status. Similarly, worker’s work capability models are used to find a suitable alternative worker to facilitate the fatigue worker.
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