Automated simulation-based workplace design that considers ergonomics and productivity

When designing a workplace with manual material handling tasks, it is important to consider both production and ergonomics. We developed an automated workplace design methodology that addresses production and ergonomics for tasks involving a handled mass of up to 23 kg. This process combines optimisation and a Digital Human Modelling (DHM) simulation, which yield the production and ergonomic measures. The task cycle time in current DHM simulations is based on Predetermined Motion Time Systems (PMTS). To address reservations about the time prediction accuracy of PMTS, we developed a new time prediction model that takes the influence of the handled mass into consideration. Our model and optimisation process were evaluated by using a case study of a box conveying workplace design. The time prediction model results did indeed agree with the real mass handling behaviour. Three design approaches (objective functions) were compared: considering only production, only ergonomics and both production and ergonomics. Each approach resulted in a different optimal solution.