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Simulation-based multi-objective optimization of productivity and worker well-being
University of Skövde, School of Engineering Science. University of Skövde, Virtual Engineering Research Environment. (User Centred Product Design (UCPD))ORCID iD: 0000-0002-3129-7076
2023 (English)Doctoral thesis, comprehensive summary (Other academic)
Abstract [en]

In industry, simulation software is used to simulate production, making it possible to predict events in production, calculate times and plan production, even in the early phases of the production development process. Software known as digital human modelling (DHM) tools can also be used to simulate humans working in production. When simulating digital human models, ergonomics evaluations can be carried out to assess whether workstation designs offer appropriate ergonomic conditions for the workers. However, simulations performed to predict and plan production are usually done separately from the human simulations performed to evaluate ergonomics. This can lead to suboptimal solutions in which a factory is optimized to improve either productivity or ergonomics. This thesis outlines the hypothesis that more optimal solutions for workstation design, layout and line balancing can be obtained in simulations by optimizing productivity and ergonomic factors simultaneously instead of considering them separately. Hence, the aim is to carry out research on the development of a simulation-based multi-objective optimization method for productivity and ergonomic factors and to realize the method as a software tool in order to test and communicate it. From an application and societal-impact perspective, the overall objective is to offer a new approach for designing production systems that focuses on both over-all system performance and the well-being of workers, reduces the effort of engineers and helps industry create more productive and sustainable workspaces.

Abstract [sv]

Simuleringsverktyg används i industrin för att simulera produktion. Det gör det möjligt att förutsäga händelser, uppskatta tider och planera produktionen, även i tidiga stadier av produktionsutvecklingsprocessen. På motsvarande vis används ergonomisimuleringsverktyg för att simulera människor som arbetar i produktionen. Ergonomisimulering kan till exempel utföras för att bedöma om utformningen av arbetsstationen erbjuder lämpliga ergonomiska förhållanden för arbetarna. Emellertid görs produktionssimuleringar vanligtvis separat från ergonomisimuleringar. Det kan leda till bristfälliga lösningar där en fabrik är optimerad för att förbättra antingen produktivitet eller ergonomi. Denna avhandling utgår från hypotesen att mer optimala lösningar för arbetsstationsutformning, layout och linje-balansering kan uppnås i simuleringar genom att samtidigt optimera produktivitetsfaktorer och ergonomiska faktorer istället för att beakta dem separat. Målet är därför att utforska utvecklingen av en simulerings- och flermålsbaserad optimeringsmetod för produktivitetsfaktorer och ergonomiska faktorer och att realisera metoden som ett mjukvaruverktyg för att testa och beskriva den. Ur ett tillämpnings- och samhällspåverkansperspektiv är det övergripande målet att erbjuda ett nytt tillvägagångssätt för att utforma produktionssystem som fokuserar på både systemprestanda och människans välbefinnande, som stödjer ingenjörer i deras dagliga arbete för att hitta goda lösningar, och hjälper industrin att skapa mer produktiva och hållbara arbetsplatser.

Place, publisher, year, edition, pages
Skövde: University of Skövde , 2023. , p. xii, 79, [125]
Series
Dissertation Series ; 56
Keywords [en]
Ergonomics, Productivity, Optimization, Simulation
National Category
Production Engineering, Human Work Science and Ergonomics
Research subject
User Centred Product Design; VF-KDO
Identifiers
URN: urn:nbn:se:his:diva-23360ISBN: 978-91-987907-0-2 (print)OAI: oai:DiVA.org:his-23360DiVA, id: diva2:1811968
Public defence
2023-12-21, ASSAR Industrial Innovation Arena (stora scenen/main stage) & online, Skövde, 09:00 (English)
Opponent
Supervisors
Part of project
Virtual factories with knowledge-driven optimization (VF-KDO), Knowledge FoundationSynergy Virtual Ergonomics (SVE), Knowledge FoundationVIVA - the Virtual Vehicle Assembler, VinnovaMOSIM – Modular Simulation of Natural Human Motions, VinnovaAvailable from: 2023-11-20 Created: 2023-11-14 Last updated: 2024-08-14Bibliographically approved
List of papers
1. Implementation of Ergonomics Evaluation Methods in a Multi-Objective Optimization Framework
Open this publication in new window or tab >>Implementation of Ergonomics Evaluation Methods in a Multi-Objective Optimization Framework
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2020 (English)In: DHM2020: Proceedings of the 6th International Digital Human Modeling Symposium, August 31 - September 2, 2020 / [ed] Lars Hanson; Dan Högberg; Erik Brolin, Amsterdam: IOS Press, 2020, p. 361-371Conference paper, Published paper (Refereed)
Abstract [en]

Simulations of future production systems enable engineers to find effective and efficient design solutions with fewer physical prototypes and fewer reconstructions. This can save development time and money and be more sustainable. Better design solutions can be found by linking simulations to multiobjective optimization methods to optimize multiple design objectives. When production systems involve manual work, humans and human activity should be included in the simulation. This can be done using digital human modeling (DHM) software which simulates humans and human activities and can be used to evaluate ergonomic conditions. This paper addresses challenges related to including existing ergonomics evaluation methods in the optimization framework. This challenge arises because ergonomics evaluation methods are typically developed to enable people to investigate ergonomic conditions by observing real work situations. The methods are rarely developed to be used by computer algorithms to draw conclusions about ergonomic conditions. This paper investigates how to adapt ergonomics evaluation methods to implement the results as objectives in the optimization framework. This paper presents a use case of optimizing a workstation using two different approaches: 1) an observational ergonomics evaluation method, and 2) a direct measurement method. Both approaches optimized two objectives: the average ergonomics results, and the 90th percentile ergonomics results.

Place, publisher, year, edition, pages
Amsterdam: IOS Press, 2020
Series
Advances in Transdisciplinary Engineering, ISSN 2352-751X, E-ISSN 2352-7528 ; 11
Keywords
Ergonomics, Optimization, DHM, Simulation
National Category
Production Engineering, Human Work Science and Ergonomics
Research subject
User Centred Product Design; Production and Automation Engineering; VF-KDO
Identifiers
urn:nbn:se:his:diva-19010 (URN)10.3233/ATDE200044 (DOI)000680825700037 ()2-s2.0-85091200988 (Scopus ID)978-1-64368-105-4 (ISBN)978-1-64368-104-7 (ISBN)
Conference
6th International Digital Human Modeling Symposium, August 31 - September 2, 2020, Skövde, Sweden
Funder
Vinnova, 41466Knowledge Foundation, 20180167
Note

CC BY-NC 4.0

Funder: Knowledge Foundation and the INFINIT research environment (KKS Dnr. 20180167). This work has been made possible with support from ITEA3 in the project MOSIM, and with the support from the Knowledge Foundation and the associated INFINIT research environment at the University of Skövde, within the Virtual Factories – KnowledgeDriven Optimization (VF-KDO) research profile and the Synergy Virtual Ergonomics (SVE) project, and by the participating organizations. This support is gratefully acknowledged.

Available from: 2020-09-08 Created: 2020-09-08 Last updated: 2024-08-28Bibliographically approved
2. Optimization of Productivity and Worker Well-Being by Using a Multi-Objective Optimization Framework
Open this publication in new window or tab >>Optimization of Productivity and Worker Well-Being by Using a Multi-Objective Optimization Framework
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2021 (English)In: IISE Transactions on Occupational Ergonomics and Human Factors, ISSN 2472-5838, Vol. 9, no 3-4, p. 143-153Article in journal (Refereed) Published
Abstract [en]

OCCUPATIONAL APPLICATIONS

Worker well-being and overall system performance are important elements in the design of production lines. However, studies of industry practice show that current design tools are unable to consider concurrently both productivity aspects (e.g., line balancing and cycle time) and worker well-being related aspects (e.g., the risk of musculoskeletal disorders). Current practice also fails to account for anthropometric diversity in the workforce and does not use the potential of multi-objective simulation-based optimization techniques. Accordingly, a framework consisting of a workflow and a digital tool was designed to assist in the proactive design of workstations to accommodate worker well-being and productivity. This framework uses state-of-the-art optimization techniques to make it easier and quicker for designers to find successful workplace design solutions. A case study to demonstrate the framework is provided

TECHNICAL ABSTRACT

Rationale: Simulation technologies are used widely in industry as they enable efficient creation, testing, and optimization of the design of products and production systems in virtual worlds. Simulations of productivity and ergonomics help companies to find optimized solutions that maintain profitability, output, quality, and worker well-being. However, these two types of simulations are typically carried out using separate tools, by persons with different roles, with different objectives. Silo effects can result, leading to slow development processes and suboptimal solutions.

Purpose: This research is related to the realization of a framework that enables the concurrent optimization of worker well-being and productivity. The framework demonstrates how digital human modeling can contribute to Ergonomics 4.0 and support a human factors centered approach in Industry 4.0. The framework also facilitates consideration of anthropometric diversity in the user group.

Methods: Design and creation methodology was used to create a framework that was applied to a case study, formulated together with industry partners, to demonstrate the functionality of the noted framework.

Results: The framework workflow has three parts: (1) Problem definition and creation of the optimization model; (2) Optimization process; and (3) Presentation and selection of results. The case study shows how the framework was used to find a workstation design optimized for both productivity and worker well-being for a diverse group of workers.

Conclusions: The framework presented allows for multi-objective optimizations of both worker well-being and productivity and was successfully applied in a welding gun use case.

Place, publisher, year, edition, pages
Taylor & Francis, 2021
Keywords
ergonomics, digital human modeling, productivity, simulation, optimization
National Category
Production Engineering, Human Work Science and Ergonomics
Research subject
User Centred Product Design; Production and Automation Engineering; VF-KDO
Identifiers
urn:nbn:se:his:diva-20699 (URN)10.1080/24725838.2021.1997834 (DOI)000716285800001 ()34724884 (PubMedID)2-s2.0-85118760617 (Scopus ID)
Funder
Vinnova
Note

CC BY 4.0

CONTACT Aitor Iriondo Pascual aitor.iriondo.pascual@his.se

Published online: 09 Nov 2021

This work has received support from ITEA3/Vinnova in the project Modular Simulation of Natural Human Motions (MOSIM), and from the Knowledge Foundation and the associated INFINIT research environment at the University of Skövde, within the Virtual Factories–Knowledge-Driven Optimization (VF-KDO) research profile and the Synergy Virtual Ergonomics (SVE) project, and from the participating organizations. This support is gratefully acknowledged.

10.1080/24725838.2021.1997834

Available from: 2021-11-15 Created: 2021-11-15 Last updated: 2024-06-19Bibliographically approved
3. Enabling Knowledge Discovery in Multi-Objective Optimizations of Worker Well-Being and Productivity
Open this publication in new window or tab >>Enabling Knowledge Discovery in Multi-Objective Optimizations of Worker Well-Being and Productivity
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2022 (English)In: Sustainability, E-ISSN 2071-1050, Vol. 14, no 9, article id 4894Article in journal (Refereed) Published
Abstract [en]

Usually, optimizing productivity and optimizing worker well-being are separate tasks performed by engineers with different roles and goals using different tools. This results in a silo effect which can lead to a slow development process and suboptimal solutions, with one of the objectives, either productivity or worker well-being, being given precedence. Moreover, studies often focus on finding the best solutions for a particular use case, and once solutions have been identified and one has been implemented, the engineers move on to analyzing the next use case. However, the knowledge obtained from previous use cases could be used to find rules of thumb for similar use cases without needing to perform new optimizations. In this study, we employed the use of data mining methods to obtain knowledge from a real-world optimization dataset of multi-objective optimizations of worker well-being and productivity with the aim to identify actionable insights for the current and future optimization cases. Using different analysis and data mining methods on the database revealed rules, as well as the relative importance of the design variables of a workstation. The generated rules have been used to identify measures to improve the welding gun workstation design.

Place, publisher, year, edition, pages
MDPI, 2022
Keywords
ergonomics, digital human modeling, productivity, simulation, optimization, knowledge discovery
National Category
Production Engineering, Human Work Science and Ergonomics Computer Sciences
Research subject
User Centred Product Design; Production and Automation Engineering; VF-KDO
Identifiers
urn:nbn:se:his:diva-21112 (URN)10.3390/su14094894 (DOI)000794536700001 ()2-s2.0-85129143963 (Scopus ID)
Funder
Vinnova, 2018-02227Knowledge Foundation, 2018-0167
Note

CC BY 4.0

Correspondence: aitor.iriondo.pascual@his.se

Funding: This work has received support from ITEA3/Vinnova in the project MOSIM (2018-02227), and from Stiftelsen för Kunskaps- och Kompetensutveckling within the Synergy Virtual Ergonomics (SVE) project (2018-0167) and the Virtual Factories–Knowledge-Driven Optimization (VF-KDO) research profile (2018-0011). This support is gratefully acknowledged.

Available from: 2022-05-02 Created: 2022-05-02 Last updated: 2024-02-22Bibliographically approved
4. Multi-objective optimisation of a logistics area in the context of factory layout planning
Open this publication in new window or tab >>Multi-objective optimisation of a logistics area in the context of factory layout planning
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2024 (English)In: Production & Manufacturing Research, ISSN 2169-3277, Vol. 12, no 1, article id 2323484Article in journal (Refereed) Published
Abstract [en]

The manufacturing factory layout planning process is commonly supported by the use of digital tools, enabling creation and testing of potential layouts before being realised in the real world. The process relies on engineers’ experience and inputs from several cross-disciplinary functions, meaning that it is subjective, iterative and prone to errors and delays. To address this issue, new tools and methods are needed to make the planning process more objective, efficient and able to consider multiple objectives simultaneously. This work suggests and demonstrates a simulation-based multi-objective optimisation approach that assists the generation and assessment of factory layout proposals, where objectives and constraints related to safety regulations, workers’ well-being and walking distance are considered simultaneously. The paper illustrates how layout planning for a logistics area can become a cross-disciplinary and transparent activity, while being automated to a higher degree, providing objective results to facilitate informed decision-making.

Place, publisher, year, edition, pages
Taylor & Francis Group, 2024
Keywords
factory layout, logistics area, multi-objective optimisation, simulation
National Category
Production Engineering, Human Work Science and Ergonomics
Research subject
User Centred Product Design; Virtual Production Development (VPD); VF-KDO
Identifiers
urn:nbn:se:his:diva-23640 (URN)10.1080/21693277.2024.2323484 (DOI)001175090400001 ()2-s2.0-85186422081 (Scopus ID)
Funder
Knowledge Foundation, 20200044Knowledge Foundation, 2018-0011
Note

CC BY 4.0

CONTACT Andreas Lind andreas.lind@his.se Global Industrial Development, Scania CV AB, Södertälje, Sweden

The authors appreciatively thank the support of Scania CV AB, the research school Smart Industry Sweden (20200044) and the research project Virtual Factories with Knowledge-Driven Optimisation (2018-0011) funded by the Knowledge Foundation via the University of Skövde. With this support the research was made possible.

The work was supported by the Stiftelsen för Kunskaps- och Kompetensutveckling [20200044]; Stiftelsen för Kunskaps- och Kompetensutveckling [2018-0011].

Available from: 2024-02-29 Created: 2024-02-29 Last updated: 2024-04-15Bibliographically approved
5. Development and initial usability evaluation of a digital tool for simulation-based multi-objective optimization of productivity and worker well-being
Open this publication in new window or tab >>Development and initial usability evaluation of a digital tool for simulation-based multi-objective optimization of productivity and worker well-being
2024 (English)In: Advanced Engineering Informatics, ISSN 1474-0346, E-ISSN 1873-5320, Vol. 62, article id 102726Article in journal (Refereed) Published
Abstract [en]

Engineers use modelling and simulation techniques to efficiently create, evaluate, and optimize design solutions.In an industrial production context, engineers often need to consider requirements related to both productivityand worker well-being in order to find successful design solutions. However, simulations related to productivityand worker well-being respectively, are typically carried out by different engineering roles, using different digitaltools. This lack of integrated work procedure could lead to inefficient development processes and suboptimaldesign solutions. Additionally, since performing multi-objective optimizations is likely to be seen as a complicated task by engineers in areas such as design engineering, production engineering, and ergonomics, requiringspecific knowledge and skills, such tasks are typically performed by engineers specialized on optimization. Thispaper presents the development and usability evaluation of a digital tool that supports engineers not specializedin optimization to define and perform simulation-based multi-objective optimizations of requirements related toboth productivity and worker well-being in an automated and simultaneous manner. The digital tool is the resultof research carried out over a period of four years, following an iterative development and assessment process bythe means of use cases, done in close collaboration with potential users of the digital tool, i.e. engineers at severalcompanies. The usability evaluation of the digital tool shows that potential users in the industry view the tool asa promising support for performing their engineering tasks in a more efficient and integrated manner.

Place, publisher, year, edition, pages
Elsevier, 2024
Keywords
Ergonomics, Digital human modelling, Productivity, Simulation, Optimization
National Category
Information Systems Production Engineering, Human Work Science and Ergonomics
Research subject
Virtual Production Development (VPD); User Centred Product Design
Identifiers
urn:nbn:se:his:diva-24410 (URN)10.1016/j.aei.2024.102726 (DOI)001279828600001 ()2-s2.0-85199261046 (Scopus ID)
Note

CC BY 4.0

Corresponding author: Aitor Iriondo Pascual

University of Skövde, School of Engineering Science, 541 28 Skövde, Sweden.

E-mail address: aitor.iriondo.pascual@his.se

Available from: 2024-08-05 Created: 2024-08-05 Last updated: 2024-10-09Bibliographically approved

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