Ergonomics and Collaborative Robotics: The synergy to prevent workload in industrial assembly tasks

Abstract: The synergy between Ergonomics and Collaborative Robotics represents a crucial and emergent framework to achieve innovative and human-centered assembly workstations. Among the various I4.0 technologies, Human-Robot Collaboration (HRC) has emerged as a cutting-edge solution to address ergonomic challenges while enhancing manufacturing productivity. Despite this potential, there is a significant gap in empirical studies on the implementation of these technologies, particularly in the context of integrating ergonomic requirements. This study aims to present real-world applications of HRC in assembly tasks performed by workers with musculoskeletal complaints, as well as to indicate future research challenges in this field. Our previous work involved the digital transformation of two real-industry workstations, mitigating musculoskeletal risk factors by the HRC implementation according to a human-centered design. During this work, ergonomic assessments of the workstations before and after the introduction of HRC were performed (e.g. the application of Inertial Measurement Units to quantify the Rapid Upper Limb Assessment score). Key performance indicators, such as production rates, were measured through time studies and direct observation. To gather additional insights into workers' well-being, questionnaires were applied. This multi-method approach revealed that the workstations with HRC resulted in (i) reduced production costs, (ii) improved ergonomic conditions, and (iii) enhanced worker well-being. Based on these previous findings, our current research is focused on creating a flexible integrated robotic system capable of executing a shared human-robot task plan and reasoning about the working conditions. This system will integrate a real-time ergonomics assessment system to track and evaluate postures and other physical indicators and extrapolate corrective measures. In our research, we intend to highlight that this synergy between Ergonomics and Collaborative Robotics underscores the continuous improvement of industrial processes while ensuring sustainable productivity and worker well-being.

Keywords: Ergonomics, Human-robot collaboration, Human-centered design, Assembly tasks

DOI: 10.54941/ahfe1005459

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