Defining the configuration of storage shelving in assembly workstations: an ergonomic tool for a parametric optimization

Abstract

The analysis and correction of working postures is an essential practice in industry. Discomforting postures and repetitive tasks could cause strain, fatigue, musculoskeletal disorders, pains, and injuries, reducing worker productivity. Several normative standards provide tools and methods for observation, evaluation, and solving critical ergonomic situations. The workstation assessment often requires the study of the actions and postures of each operator related to each task and each repetitive cycle. In the context of assembly line workstations, a common task is the material picking from storage shelving. The ergonomic evaluation of shelving for lineside temporary parts storage is focused on the layout, location of each part container, and picking frequencies. An ergonomic evaluation in the shelving design phase could reduce the risk of repetitive and poor working postures, producing benefits for the operators.The paper proposes a parametric optimization tool based on a Genetic Algorithm to reduce the ergonomic risks related to the picking phase from light shelves employed in assembly lines. RULA and OWAS methods are used to perform the ergonomic evaluation of different configurations of shelves during the optimization analysis. As a test case, the design of a light shelving is proposed considering the time and assembly cycle of fitness bikes.

Keywords: Ergonomics, RULA, OWAS, Design Optimization, Genetic Algorithm, Industrial Shelving

DOI: 10.54941/ahfe1004807