An automated simulation approach for productive and ergonomic workplace design

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Work-related Musculoskeletal Disorders (WMSDs) is one of the most common injuries. WMSDs are associated with high cost burdens to employers due to absenteeism, lost productivity, and increased health care, and workers' compensation costs. As a large steel fabrication and construction firm, Waiward also faces various challenges related to WMSDs. A high number of tasks are performed by workers at Waiward's six fabrication shops in two ten-hour shifts per day. Due to the nature of the steel fabrication process, many of these tasks pose a high degree of ergonomic risk and can lead to WMSDs. The company statistics estimate WMSDs to account for more than 40% of their total workplace injuries. The aim of the proposed research is thus to improve worker safety at Waiward by integrating productivity improvement techniques and ergonomic analysis through automation. Specifically, this research proposes motion data-based ergonomic analysis and micro-motion level simulation to take both productivity and safety into account for operation planning and monitoring. The objective of this study will be achieved through the following four phases: (1) physical demand analysis to identify ergonomically awkward postures, (2) automated biomechanical simulation to identify specific body joints with excessive physical demand, (3) time studies and simulation modelling to assess job efficiency, and (4) simulation platform development to integrate productivity and safety into operation analysis. The anticipated contribution is (1) to provide insight into safety as an emergent property of a production system, (2) to explore a micro-motion level simulation approach that ensures productive and reliable operation analysis, (3) to investigate an automated means of ergonomic analysis using motion capture data, and, (4) to propose a novel method to measure job efficiency based on standardized motion time data. The broader impacts of this research include the prevention of injuries and the preservation of human well-being in various industries where labour is an important resource. It also provides an innovative research methodology that will aid understanding of human behavior in workplaces.