Human factors and ergonomics

The so-called smart manufacturing systems (SMS) combine smart manufacturing technologies, cyber-physical infrastructures, and data control to realize predictive and adaptive behaviours. In this context, industrial research focused mainly on improving the manufacturing system performance, almost neglecting human factors (HF) and their relation to the production systems. However, in order to create an effective smart factory context, human performance should be included to drive smart system adaptation in efficient and effective way, also by exploiting the linkages between tangible and intangible entities offered by Industry 4.0. Furthermore, modern companies are facing another interesting trend: aging workers. The age of workers is generally growing up and, consequently, the percentage of working 45–64 years old population with different needs, capabilities, and reactions, is increasing. This research focuses on the design of human-centred adaptive manufacturing systems (AMS) for the modern companies, where aging workers are more and more common. In particular, it defines a methodology to design AMS able to adapt to the aging workers' needs considering their reduced workability, due to both physical and cognitive functional decrease, with the final aim to improve the human-machine interaction and the workers' wellbeing. The paper finally presents an industrial case study focusing on the woodworking sector, where an existing machine has been re-designed to define a new human-centred AMS. The new machine has been engineered and prototyped by adopting cyber-physical systems (CPS) and pervasive technologies to smartly adapt the machine behaviour to the working conditions and the specific workers' skills, tasks, and cognitive-physical abilities, with the final aim to support aging workers. The achieved benefits were expressed in terms of system usability, focusing on human-interaction quality.

Keywords: Adaptive manufacturing systems , Aging workers , Cyber-physical systems , Human factors , Smart manufacturing systems , Usability

Although factories are becoming smarter and more and more automated, thanks to ICT penetration, process performances still highly depend on 'humans in the loop' who have to carry out their tasks by perceiving and understanding increasingly complex multidimensional data sets. Forecasting the human behaviours and assessing how human factors affect the process performance are very difficult but fundamental for strategic decision-making and sustainable manufacturing. In this context, the research highlights the need of predictive methods to design human-centred smart manufacturing systems from the early design stages as an important part of the overall assessment of process sustainability. The paper defines a model to early assess human factors to be integrated with other existing models (i.e., cost estimation and lifecycle assessment) to evaluate manufacturing process sustainability. The proposed integrated method can be fruitfully used to support the design of sustainable manufacturing systems by taking into account also the impact on workers. An industrial case study focusing on packaging machines design is presented to demonstrate the validity of the proposed method and its adoption to propose re-design action promoting sustainability.

Keywords: Design for sustainability , Human factors , Key performance indicators , KPIs , Sm , Sustainability assessment , Sustainable manufacturing

Nevertheless process automation is a global trend, some specific phases (i.e., assembly) in highly technological sectors (i.e., medical, pharmaceutical, diagnostics, dental) are still managed by human workers, due to high-precision tasks and low production volumes. In this context, operators are forced to work faster and adapt to not ergonomically workstations and workflows. As a consequence, human assembly is frequently the bottleneck of the entire process due a not ergonomic layout and process design. The study was conducted at a medical equipment manufacturer, leader of dental equipment production, and focused on the analysis of the assembly process of the dental units. Workers at the assembly line were observed by experts and involved also by interviews and focus groups to detect the assembly issues and process jam. The research provides a valuable example of how physical, cognitive and organizational ergonomic problems affect the final process performance and how human-oriented re-design actions can be easily defined according to the proposed analysis procedure.

Keywords: Assembly workstation design , Design optimization , Ergonomics , Human Factors , Humancentred design

The analysis of human factors is assuming an increasing importance in product and process design and the lack of common references for their assessment in industrial practices had driven to define a reference model to analyse the so-called User eXperience (UX) to support human-centred product-process design. Indeed, the recent advances in ubiquitous computing, wearable technologies and low-cost connected devices offer a huge amount of new tools for UX monitoring, but the main open issue is selecting the most proper devices for the specific application area and properly interpreting the collected information content in respect with the industrial design goals. The research investigates how to analyse the human behaviours of "users" (i.e., workers) by a reference model to assess the perceived experience and a set of proper technologies for UX investigation for industrial scopes. In particular, the model has been defined for the automotive sector. The paper defines a set of evaluation metrics and a structured protocol analysis to objectify and measure the UX with the final aim to support the requirements definition in product-process design. The model has been defined to fit different cases: vehicle drivers at work, workers in the manufacturing line, and service operators.

Keywords: Digital mock-ups , Human Factors , Integrated product-process design , Protocol analysis , User eXperience

Industry 4.0 paradigm is based on systems communication and cooperation with each other and with humans in real time to improve process performances in terms of productivity, security, energy efficiency, and cost. Although industrial processes are more and more automated, human performance is still the main responsible for product quality and factory productivity. In this context, understanding how workers interact with production systems and how they experience the factory environment is fundamental to properly model the human interaction and optimize the processes. This research investigates the available technologies to monitor the user experience (UX) and defines a set of tools to be applied in the Industry 4.0 scenario to assure the workers' wellbeing, safety and satisfaction and improve the overall factory performance.

Keywords: Human Factors , Human Interaction , Industry 4.0 , Production system design , User experience

In order to achieve more sustainable development processes, industries need not only to improve energy efficiency and reduce costs, but also to increase the operators' wellbeing to promote social sustainability. In this context, the present research focuses on the definition of a methodology based on human-centred virtual simulation to improve the social sustainability of maintenance tasks by enhancing system design and improving its serviceability. It is based on the operators' involvement and the analysis of their needs from the early design stages on virtual mock-ups. The methodology proposed merges a protocol analysis for human factors assessment and an immersive virtual simulation where immersive serviceability simulations can be used during design phases. To demonstrate the effectiveness of the proposed method, an industrial use case has been carried out in collaboration with CNH Industrial.

Keywords: Ergonomics , Human-Centred Design (HCD) , Serviceability , Sustainability , Virtual simulation

Requirement management represents one of the key process in the complex product life cycle because it is involved not only at the beginning, but also in the further phases where the definition of the technical specifications sometimes implicates requirements tradeoff due to conflicts. For this reason the role of RM tools and methodologies, that normally represents a stand-alone solution, has to change and to be more integrated in the Product Lifecycle Management platform. At present a real shared integrated RM solution doesn't exist and for this reason it is necessary to provide a framework for supporting the customization of the available RM solutions for catching the real and specific company needs in this new collaborative scenario. For this reason this paper presents a methodical approach that incorporates user-centered design principles into the customization process of the tool. It permits to be adopted in each possible company scenario thanks to its ability to catch the company specific needs and further identifying the right features for the company. The proposed methodology puts the user, rather than the system, at the center of the process because the RM solution could be considered effective only if it is able to save time and money in the data management by users. Moreover, this tool assessment method can help organizations efficiently determine candidate tools, to understand what is important in that organization and to make a tool selection customized for their needs. The case study on Requirement Management tools as Part of Product Lifecycle Management (PLM) Solution is presented.

Keywords: Kano model , Product Lifecycle Management (PLM) , Quality function deployment (QFD) , Requirement Management (RM) , User-centered design

This paper presents a method for posture prediction of the upper trunk of video terminal (VDT) operators, which is then verified by means of some test cases. The prediction of the upper trunk posture is, in fact, a very difficult task to carry out due mainly to the complexity of the anatomy of the spine and the surrounding muscles. The method being proposed in this paper is based on the integration of the knowledge which is obtained experimentally through the posture analysis of real cases into a configured human multi-body kinematic model which has been implemented in a commercial CAD system. A trained artificial neural network retains the knowledge concerning the VDT operator's postures detected in different working positions. The posture simulations obtained with the proposed method are subsequently compared with the real ones determined by a 3D scanner. The results obtained confirm the effectiveness of such a method, which is deemed promising to implement other anthropometric data and further human poses.

Keywords: Artificial neural network , Ergonomics , Multi-body virtual human models , Posture prediction

The aim of this paper was to investigate prerequisites for safety equipment in the surrounding area of soccer playing-fields. Therefore, the frequency and location of overstepping boundary line events (OBEs) occurring when football players are crossing the boundary lines and leaving the regular field. Commercial television video footage of 28 matches in UEFA European Championship 2012 and of 46 matches in FIFA World Cup 2006 were analysed. To accurately identify portions of playfield outline where an OBE occurred, the four different field lines, two Goal lines and two Side lines were divided in 46 segments, defined as “boundary-line-segment” (BLS). Statistical analysis was used to prove if OBEs were uniformly distributed over all playfield BLSs. The results indicated remarkable differences in OBE frequencies among football field areas. In particular, goal-line-BLSs have shown to be the most critical zones of the pitch outline, with different number of OBEs on the two goal lines. This opposes the expected symmetry in OBE distribution as a consequence of the usually adopted directions of football playing and equal boundary areas surrounding goal posts. Furthermore, absolute OBE frequencies on Side line near to the technical area appeared to be greater than the homologues on the opposite side line. The distribution pattern of OBEs over all BLS can be explained by two main influencing effects: the side line effect (SLE—players behave differently at the sideline of the technical area compared to opposite side line because of different distance to advertisements boards) and the leg side effect (LSE—most players prefer to use their right leg to kick the ball). Findings in terms of OBE frequencies should be taken into account to establish right priority of actions for safety intervention by responsible and technicians of Sports fields.

Keywords: Boundary lines , Football , Impact , Match analysis , Safety

Aim of this study was to validate an inertial system able to detect the loss of ground contact (LOGC) in race-walking through outdoor tests in real training conditions. An inertial sensor was placed at L5/S1 of the vertebral column of a Italian national team athlete to acquire timing measurements of the LOGC. Data were encoded by a well-defined protocol. After a preliminary laboratory study, the athlete performed outdoor-field-tests at different velocities. A specific e-bike with a high-speed camera allowed to acquire a video and to validate sensor measurements. Results indicate that the inertial system can improve the accuracy in detecting the visible LOGC.

Keywords: inertial sensor , loss of contact , outdoor test , Race walking , video analysis

This paper presents a method, which integrates digital human models (DHM) and virtual prototyping techniques to analyse ergonomic issues of devices to be used by workers. It is based on the comparison between the analysis of AS-IS and TO-BE scenarios with the aim of assessing design concepts, highlighting improvements or worsening and residual deficiencies to be faced. In particular, this paper refers to the case study of display units for groceries or supermarkets. Actually, workers who are in charge of filling the shelves perform highly repeated tasks, potentially dangerous for their health. The AS-IS and TO-BE analysis compares the actual practices with a new scenario in which workers are provided with lifting platforms to load the shelves. The method allows assessing several ergonomics parameters; in this study posture and fatigue are the most relevant. The results achieved with the simulations permitted to propose alternative solutions. Future works in this field concern the standardisation of domain dependant actions virtual human are asked to perform.

Keywords: Design validation , DHM , Digital human models , Display unit , Ergonomics analysis , Fatigue , Lifting AIDS , NIOSH , OWAS , Posture

Concerning quiet areas, the definition provided by the Environmental Noise Directive (END) is intended to preserve the acoustic environment in those areas where it is considered good, according to general indicators and limits. However, the END is not clear enough to allow appropriate assessment and management in urban environments. The aim of QUADMAP project was to deliver a method and guidelines for the identification, delineation, characterization, improvement and management of Quiet Urban Areas (QUAs) as defined by the END. The Project also wanted to help clarify the definition of a QUA, its meaning and its added value for cities in terms of health, safety and lowering stress levels. In this article, after an introduction of the current European scenario on QUAs, the main aspects of the methodology introduced for the selection, analysis and management of QUAs are described. Eventually, the major results achieved by the Project, in terms of the guideline on QUAs, the implemented interventions and the achieved benefits, are reported and discussed.

Keywords: Action plan , Environmental noise , Noise mapping , Quiet areas , Soundscape

The European Noise Directive 2002/49/EC (END) provides indications and recommendations about noise mapping, action planning, quiet areas and the communication and dissemination towards citizens. However, for several items only definitions and general indications are made available, without giving specific suggestions about how to deal with them in practice. In this article the main contributions to END interpretation and implementation from the Italian case studies of EU funded projects HUSH, NADIA and QUADMAP are described. LIFE+2008 HUSH (Harmonization of Urban Noise reduction Strategies for Homogeneous action plans) project aimed at giving a contribution to the harmonization of the National and European legislations, regarding urban noise management tools, allowing a definition of coherent procedures able to comply the commitments introduced by National laws and by the END. Starting from the methodology defined and the interventions realized in two pilot areas in Florence, proposals for revision of National legislation and END have been provided, for supporting competent authorities and policy makers. In the LIFE+2009 NADIA (Noise Abatement Demonstrative and Innovative Actions and information to the public) project methods and procedures to achieve the END requirements have been developed, aiming the following main objectives: to improve the methodologies for the realization of noise mappings and action plans, with a particular focus on road traffic noise, to increase the awareness of citizens and of potential stakeholders by focused communication and dissemination activities and to assess the technical and economic feasibility of best practices in tackling road traffic noise. LIFE+2010 QUADMAP project (QUiet Areas Definition and Management in Action Plans) has proposed a method and guidelines for the selection, analysis and management of Quiet Urban Areas (QUAs) as introduced by the END.

This paper presents a novel system that allows product designers to design, experience, and modify new shapes of objects, starting from existing ones. The system allows designers to acquire and reconstruct the 3D model of a real object and to visualize and physically interact with this model. In addition, the system allows designer to modify the shape through physical manipulation of the 3D model and to eventually print it using a 3D printing technology. The system is developed by integrating state-of-the-art technologies in the sectors of reverse engineering, virtual reality, and haptic technology. The 3D model of an object is reconstructed by scanning its shape by means of a 3D scanning device. Then, the 3D model is imported into the virtual reality environment, which is used to render the 3D model of the object through an immersive head mounted display (HMD). The user can physically interact with the 3D model by using the desktop haptic strip for shape design (DHSSD), a 6 degrees of freedom servo-actuated developable metallic strip, which reproduces cross-sectional curves of 3D virtual objects. The DHSSD device is controlled by means of hand gestures recognized by a leap motion sensor.

The paper presents an integrated technological framework, which aims to make a step forward in contract furniture design methods and supporting web-enabling applications. The implementing platform enables the extensible and temporary cluster of companies to manage the entire contract furniture process. The main contribution regards the integration of different software modules into an overall system that exploits E-marketing Intelligence applications, 3D web-based tools and Augmented Reality techniques. Different user interfaces are implemented to accomplish the involved stakeholders needs and furniture development goals.

Keywords: Collaborative Product Development , E-marketing , Web-enabled design

The sense of smell has a great importance in our daily life. Recently, smells have been used for marketing purposes for improving the people's mood and for communicating information about products as household cleaners and food. However, the scent design discipline can be used for creating a "scent identity" of these products not traditionally associated to a specific smell, in order to communicate their features to customers. In the area of virtual reality (VR), several researches concerned the integration of smells in virtual environments. The research questions addressed in this paper concern if virtual prototypes (VP), including smell simulation, can be used for evaluating products as effectively as studies performed in real environments, and also if smells can enhance the users' sense of presence in virtual environments. For this purpose, a VR experimental framework including a prototype of a wearable olfactory display (wOD) has been set up, and experimental tests have been carried out.

The sense of smell has a great importance in our daily life. In recent years, scents have been used for marketing purposes for improving the person's mood and of communicating information about products as household cleaners and food. However, scents can be also used for any kind of products to communicate their features to customers. In the area of Virtual Reality several researches have focused on integrating scents in virtual environments. The research questions addressed in this work concern if scents can contribute to increase the users' sense of presence in the virtual environment, and also if Virtual Prototypes, including the sense of smell, can be used for evaluating products as effectively as studies performed in real environments. For this purpose, a Virtual Reality experimental framework including a prototype of a Wearable Olfactory Display has been set up, and experimental tests have been performed.

Keywords: Multisensory environment , olfactory display , product evaluation

The paper describes a system to supply meaningful insights to designers during the concept generation of new car interiors. The aim of the system is to capture the movements of car passenger's and making these acquisitions directly available as a generative input. The system has been developed by integrating the Abstract Prototyping technique with Motion Capture technology. In addition, a systematic procedure allows the treatment of the collected data to obtain a graphical representation, which can be easily used with standard NURBS-based modeling software. The effectiveness of the system has been evaluated through a testing session conducted with subjects. The outcomes of the testing sessions have highlighted benefits and limitations of the implemented system.

Keywords: Abstract prototyping , human factors , motion capture