Search Results (12)

This review provides a comprehensive analysis of studies investigating the impact of occupational exoskeletons on work-related musculoskeletal disorder (WMSD) risk factors. The primary objective is to examine the methodologies used to assess the effectiveness of these devices across various occupational tasks. A systematic review was conducted following the PRISMA guidelines, covering studies published between 2014 and 2024. A total of 49 studies were included, identified through searches conducted in Scopus and Web of Science databases, with the search string launched in August 2024. The review identifies a growing body of research on passive and active exoskeletons, with a notable focus on laboratory-based evaluations. The results indicate that direct measurement and self-report methods are the preferred approaches in these domains. Ergonomic limitations and user discomfort remain concerns in some cases. The findings of this review may influence stakeholders by providing insights into the potential benefits of adopting exoskeletons and improving workplace ergonomics to reduce WMSD risks. Additionally, the identification of WMSD assessment methods will be valuable for validating the use of these technologies in the workplace. The review concludes with recommendations for future research, emphasizing the need for more real-world assessments and improved exoskeleton designs to enhance user comfort and efficacy. Full article

The field of ergonomics has been significantly shaped by the advent of evolving technologies linked to new industrial paradigms, often referred to as Industry 4.0 (I4.0) and, more recently, Industry 5.0 (I5.0). Consequently, several studies have reviewed the integration of advanced technologies for improved ergonomics in different industry sectors. However, studies often evaluate specific technologies, such as extended reality (XR), wearables, artificial intelligence (AI), and collaborative robot (cobot), and their advantages and problems. In this sense, there is a lack of research exploring the state of the art of I4.0 and I5.0 virtual and digital technologies in evaluating work-related biomechanical risks. Addressing this research gap, this study presents a comprehensive review of 24 commercial tools and 10 academic studies focusing on work-related biomechanical risk assessment using digital and virtual technologies. The analysis reveals that AI and digital human modelling (DHM) are the most commonly utilised technologies in commercial tools, followed by motion capture (MoCap) and virtual reality (VR). Discrepancies were found between commercial tools and academic studies. However, the study acknowledges limitations, including potential biases in sample selection and search methodology. Future research directions include enhancing transparency in commercial tool validation processes, examining the broader impact of emerging technologies on ergonomics, and considering human-centred design principles in technology integration. These findings contribute to a deeper understanding of the evolving landscape of biomechanical risk assessment. Full article

Logistics activities involve significant risk factors for the development of work-related musculoskeletal disorders (WMSD), particularly low back pain. Exoskeletons have emerged as potential solutions to mitigate these risks. This study assesses the short-term effects of dual passive back-support exoskeletons (Auxivo and Htrius) on WMSD risk factors in logistics operations. Two workstations were evaluated using self-report ratings, postural assessment, and surface electromyography (EMG). The results indicate that both exoskeletons provided relief and support during tasks, with Htrius showing a slight advantage. Exoskeletons reduced perceived exertion, especially during trunk flexion tasks, and improved posture, particularly in tasks involving manual lifting loads at lower height levels. While variations in muscular activity were observed, the Htrius exoskeleton showed a trend of reducing lumbar muscle activity. Overall, Htrius demonstrated promise in improving workers’ comfort, safety, and efficiency, potentially reducing WMSD risk and muscular fatigue. However, individual preferences and workplace-specific characteristics should be considered when selecting exoskeleton models. Future research should explore the effects on different loads, genders, and EMG of different muscles to further enhance the understanding and application of exoskeletons in occupational contexts. Full article

Work-related musculoskeletal disorders (WMSD) are highly prevalent among supermarket cashiers. These disorders are frequently related to the adoption of awkward postures and manual materials handling. This study aimed to analyze musculoskeletal loadings in supermarket cashiers, considering the handling of different products and different checkout conditions. To accomplish this, we employed an inertial motion capture system to measure full-body kinematics while simulating 19 cashier tasks. The study included five female cashiers from a supermarket in Northern Portugal, ranging in age from 19 to 61 years old. Using joint angles, material load, and muscle function as input parameters, we conducted the musculoskeletal loadings assessment using the Rapid Upper Limb Assessment (RULA) and Rapid Entire Body Assessment (REBA) methods. Results showed that RULA scores were higher for the microtasks that involved product scanning. Regarding microstasks analyzed by REBA, the replacement of paper rolls for the receipt machine at the checkout counter yields the highest scores. Based on these findings, there is a compelling need to redesign supermarket checkout workstations to alleviate the physical demands placed on cashiers and to ensure organizational sustainability. Full article

In aircraft manufacturing settings, workers are frequently exposed to biomechanical risk factors, mainly in the later stages of the production processes, including inspection tasks. To support the development of a novel inspection device appropriate for the end-users and their tasks, this study presents a user-centered approach for the device’s handle. Three different handles were proposed, and the current study aims to find out which handle can offer (1) the best ergonomic conditions and (2) the best stability in holding the device in hand during an inspection task. To this end, 23 volunteers participated in the experimental assessment, which comprised qualitative and quantitative data. A questionnaire was used for subjective comfort assessment. Partial times to execute the task studied, stability metrics of the device during its handling, and kinematic and electromyographic data of the upper limb recruited were measured and analyzed to compare the three handles. Outstanding results include the higher comfort perceived by the participants working with the selected handle for the final design, as well as the reduction in muscle effort. Globally, the results obtained demonstrated that the handle user-centered design potentiates good efficiency and usability of the novel device. Full article

In environments shared with humans, Autonomous Mobile Robots (AMRs) should be designed with human-aware motion-planning skills. Even when AMRs can effectively avoid humans, only a handful of studies have evaluated the human perception of mobile robots. To establish appropriate non-verbal communication, robot movement should be legible and should consider the human element. In this paper, a study that evaluates humans’ perceptions of different AMR courtesy behaviors at industrial facilities, particularly at crossing areas, is presented. To evaluate the proposed kinesic courtesy cues, we proposed five tests (four proposed cues—stop, deceleration, retreating, and retreating and moving aside—and one control test) with a set of participants taken two by two. We assessed three different metrics, namely, the participants’ self-reported trust in AMR behavior, the legibility of the courtesy cues in the participants’ opinions, and the behavioral analysis of the participants related to each courtesy cue tested. The retreating courtesy cue, regarding the legibility of the AMR behavior, and the decelerate courtesy cue, regarding the behavioral analysis of the participants’ signs of hesitation, are better perceived from the forward view. The results obtained regarding the participants’ self-reported trust showed no significant differences in the two participant perspectives. Full article

Human-Robot Collaboration (HRC) systems are often implemented seeking for reducing risk of Work-related Musculoskeletal Disorders (WMSD) development and increasing productivity. The challenge is to successfully implement an industrial HRC to manage those factors, considering that non-linear behaviors of complex systems can produce counterintuitive effects. Therefore, the aim of this study was to design a decision-making framework considering the key ergonomic methods and using a computational model for simulations. It considered the main systemic influences when implementing a collaborative robot (cobot) into a production system and simulated scenarios of productivity and WMSD risk. In order to verify whether the computational model for simulating scenarios would be useful in the framework, a case study in a manual assembly workstation was conducted. The results show that both cycle time and WMSD risk depend on the Level of Collaboration (LoC). The proposed framework helps deciding which cobot to implement in a context of industrial assembly process. System dynamics were used to understand the actual behavior of all factors and to predict scenarios. Finally, the framework presented a clear roadmap for the future development of an industrial HRC system, drastically reducing risk management in decision-making. Full article

The ergonomic assessment of adopted working postures is essential for avoiding musculoskeletal risk factors in manufacturing contexts. Several observational methods based on external analyst observations are available; however, they are relatively subjective and suffer low repeatability. Over the past decade, the digitalization of this assessment has received high research interest. Robotic applications have the potential to lighten workers’ workload and improve working conditions. Therefore, this work presents a musculoskeletal risk assessment before and after robotic implementation in an assembly workstation. We also emphasize the importance of using novel and non-intrusive technologies for musculoskeletal risk assessment. A kinematic study was conducted using inertial motion units (IMU) in a convenience sample of two workers during their normal performance of assembly work cycles. The musculoskeletal risk was estimated according to a semi-automated solution, called the Rapid Upper Limb Assessment (RULA) report. Based on previous musculoskeletal problems reported by the company, the assessment centered on the kinematic analysis of functional wrist movements (flexion/extension, ulnar/radial deviation, and pronation/supination). The results of the RULA report showed a reduction in musculoskeletal risk using robotic-assisted assembly. Regarding the kinematic analysis of the wrist during robotic-assisted tasks, a significant posture improvement of 20–45% was registered (considering the angular deviations relative to the neutral wrist position). The results obtained by direct measurements simultaneously reflect the workload and individual characteristics. The current study highlights the importance of an in-field instrumented assessment of musculoskeletal risk and the limitations of the system applied (e.g., unsuitable for tracking the motion of small joints, such as the fingers). Full article

There is a worldwide interest in implementing collaborative robots (Cobots) to reduce work-related Musculoskeletal Disorders (WMSD) risk. While prior work in this field has recognized the importance of considering Ergonomics & Human Factors (E&HF) in the design phase, most works tend to highlight workstations’ improvements due to Human-Robot Collaboration (HRC). Based on a literature review, the current study summarises studies where E&HF was considered a requirement rather than an output. In this article, the authors are interested in understanding the existing studies focused on Cobots’ implementation with ergonomic requirements, and the methods applied to design safer collaborative workstations. This review was performed in four prominent publications databases: Scopus, Web of Science, Pubmed, and Google Scholar, searching for the keywords ‘Collaborative robots’ or ‘Cobots’ or ‘HRC’ and ‘Ergonomics’ or ‘Human factors’. Based on the inclusion criterion, 20 articles were reviewed, and the main conclusions of each are provided. Additionally, the focus was given to the segmentation between studies considering E&HF during the design phase of HRC systems and studies applying E&HF in real-time on HRC systems. The results demonstrate the novelty of this topic, especially of the real-time applications of ergonomics as a requirement. Globally, the results of the reviewed studies showed the potential of E&HF requirements integrated into HRC systems as a relevant input for reducing WMSD risk. Full article

One of the key interesting features of collaborative robotic applications is the potential to lighten the worker workload and potentiate better working conditions. Moreover, developing robotics applications that meets ergonomic criteria is not always a straightforward endeavor. We propose a framework to guide the safe design and conceptualization of ergonomic-driven collaborative robotics workstations. A multi-disciplinary approach involving robotics and ergonomics and human factors shaped this methodology that leads future engineers through the digital transformation of a manual assembly (with repetitive and hazardous operations) to a hybrid workstation, focusing on the physical ergonomic improvement. The framework follows four main steps, (i) the characterization of the initial condition, (ii) the risk assessment, (iii) the definition of requirements for a safe design, and (iv) the conceptualization of the hybrid workstation with all the normative implications it entails. We applied this methodology to a case study in an assembly workstation of a furniture manufacturing company. Results show that the methodology adopted sets an adequate foundation to accelerate the design and development of new human-centered collaborative robotic workstations. Full article

Lean Manufacturing (LM), Ergonomics and Human Factors (E&HF), and Human–Robot Collaboration (HRC) are vibrant topics for researchers and companies. Among other emergent technologies, collaborative robotics is an innovative solution to reduce ergonomic concerns and improve manufacturing productivity. However, there is a lack of studies providing empirical evidence about the implementation of these technologies, with little or no consideration for E&HF. This study analyzes an industrial implementation of a collaborative robotic workstation for assembly tasks performed by workers with musculoskeletal complaints through a synergistic integration of E&HF and LM principles. We assessed the workstation before and after the implementation of robotic technology and measured different key performance indicators (e.g., production rate) through a time study and direct observation. We considered 40 postures adopted during the assembly tasks and applied three assessment methods: Rapid Upper Limb Assessment, Revised Strain Index, and Key Indicator Method. Furthermore, we conducted a questionnaire to collect more indicators of workers’ wellbeing. This multi-method approach demonstrated that the hybrid workstation achieved: (i) a reduction of production times; (ii) an improvement of ergonomic conditions; and (iii) an enhancement of workers’ wellbeing. This ergonomic lean study based on human-centered principles proved to be a valid and efficient method to implement and assess collaborative workstations, foreseeing the continuous improvement of the involved processes. Full article

Work-related musculoskeletal disorders (WMSD) are one of the main occupational health problems. The best strategy to prevent them lies on ergonomic interventions. The variety of industrial processes and environments, however, makes it difficult to define an all-purpose framework to guide these ergonomic interventions. This undefinition is exacerbated by recurrent introduction of new technologies, e.g., collaborative robots. In this paper, we propose a framework to guide ergonomics and human factors practitioners through all stages of assessment and redesign of workstations. This framework was applied in a case study at an assembly workstation of a large furniture enterprise. Direct observation of work activity and questionnaires were applied to characterize the workstations, the process, and the workers’ profiles and perceptions. An ergonomic multi-method approach, based on well-known and validated methods (such as the Finnish Institute of Occupational Health and Rapid Upper Limb Assessment), was applied to identify the most critical risk factors. We concluded that this approach supports the process redesign and tasks’ allocation of the future workstation. From these conclusions, we distill a list of requirements for the creation of a collaborative robot cell, specifying which tasks are performed by whom, as well as the scheduling of the human-robot collaboration (HRC). Full article