Principles of a new methodology for industrial workplaces design.

Bures, Marek

1. INTRODUCTION

The main goal is creation of universally valid methodology for digital ergonomic design and evaluation of workplaces in industrial companies namely in big as well as middle sized and small companies. As the title suggests the methodology is divided into two parts. It is either the part for design of a completely new workplace which didn't exist before or evaluation of a workplace which already exists. Though the both parts are similar and uses the same information, the algorithm progression is different in individual parts. This methodology has three fundamental parts, which are:

* Algorithm

* Knowledge rule base

* Software support

This issue is according to my opinion very actual. There are so few real ergonomic experts in praxis. Unlike some other European Union countries, where there are special study programs or directly accredited representatives, where student get Eur. Erg. degree after completing the course, in the Czech Republic this does not exist. There is no problem to use proper literature for ergonomic evaluation of workplaces but this is in many times quite difficult according to considerable expertness of the text and huge amount of information.

2. STATE OF THE ART

Several authors (Chundela, 1993; Kral, 2002; Matousek & Zastavka, 1977; REFA, 1991; Hlavenka, 1995) have already tried in past years to describe from different points of view the methodology how to progress during the workplace design. Some of these authors stick rather to technical and constructional approach, some use the rationalization point of view and some use the classical ergonomic approach. These methodologies are hence always marked with certain amount of subjectivity and miss the holistic approach. Also none of these methodologies contain all of the crutial aspects that must be respected.

Further more we can use huge amount of analyses, which solve individual workplace aspects. The planer has simple checklists in these days at disposal as well as complex analyses like RULA, REBA, PLIBEL, lifting, lowering, pushing, and pulling analysis from NIOSH or Snook and many others. However the problem is still the same and that is possibility to apply these analyses only for concrete task. Last but not least we must include into the design and evaluation of the workplaces the information from legislative regulations and norms. Studying all of these sources is essential for creation of a new methodology, which must in the first place ensure the complex view on design and evaluation of the workplaces.

Software tools resolving the ergonomic issue are the last area of my interest. Nowadays the absolute peaks on the field of ergonomic studies are software Delmia V5 Human from Dassault Systemes company, Tecnomatix Jack from Siemens company and software Ramsis from Human solutions company. These products integrate all last trends and knowledge not only from the area of ergonomic and that's why they must not be ignored.

3. FUNDAMENTAL PARTS OF THE METHODOLOGY

The backbone of suggested methodology is an algorithm that clearly formulates all processes and steps regarding design and evaluation of a workplaces. By analysing accessible methodologies I came to conclusion that there are only different modifications of the same idea. All methodologies respect the same common outline and it always represents only common description how to proceed during the workplace design. It isn't enough according to my opinion because common description enables considerable variability. My effort is transparent representation of all crucial and concrete steps during the workplace design which have influence on resulting effect and that clearly and unambiguously determines succession of these steps. This solution contributes to better explanation for people who aren't directly specialists in ergonomics. They will be then able to carry out competent design or evaluation of the workplace.

Below there are written the basic, in these days generally known, algorithm steps that must be observed for effective design and evaluation of the workplaces.

1) Goals formulation

2) Workplace diagnosis

3) Data collection

4) Solution proposal--creation of variants

5) Assignment of evaluating criteria

6) Selection of optimal variant

7) Preparation of documentation

8) Realization

9) Control and correction

Resulting shape of the algorithm will be elaborated with the help of Microsoft Visio program.

The algorithm gives only progression of the individual steps. The second necessary part of the whole methodology is the knowledge rule base that serves for well-arranged representation of all important aspects and rules during the workplace design. This knowledge rule base contains all immediately important principles and rules. The algorithm is in concrete steps only using the information contained in the knowledge rule base. The whole design process will be speeded up thanks to the concrete values of single ergonomic parameters that are contained in the knowledge base. There will be no need to search appropriate values in the literature or norms, because all the basic and essential values will be included here.

During selection of ergonomic criteria, which have influence on design and evaluation of the workplaces, I came out from well known linkage man--machine--medium and I divided the criteria into three main areas: anthropometrical criteria, criteria regarding workplace and environment criteria. Further more it is important to append this classical triangle with other areas, which have direct influence on workplace design or must be considered, because have influence on workers comfort and performance. All of these criteria are transparently illustrated with the help of Ishikawa diagram. This structured view on particular problem helps not only by determining significant causes, but also by searching mutual connections.

All mentioned criteria are included in the knowledge rule base in the form of sheets that are containing the concrete parameters. During creation of the single sheets I came out from literature, norms and legislative regulations and registered only the most important facts immediately needed for workplace design and evaluation in the industrial manufacturing area. I assume that by this approach I was able to observe briefness and high predicative ability of this rule base.

I also expect that the final methodology will be quite extensive and for somebody maybe also hard to understand. This is the reason why I designated the creation of support software, which will ensure the user accessibility, as the last goal. The appropriate software tool for methodology description wasn't chosen yet. One of the key deciding factors will be the final form of the algorithm. There are several possibilities. The simplest way is to use spreadsheet program like MS Excel for example. If the algorithm and the knowledge rule base is extensive and complicated, it will be possible to use more suitable database system (e.g. MS Access) for methodology description. Web applications are other possibilities.

It is clear that if there is in the future selection of any kind of system, it will have to ensure communication between algorithm and individual rule base sheets. Algorithm, which will be the backbone of this system, will ensure fulfilment of single steps and observance of their order. The user friendly evaluating outputs, which will serve as the indicators by workplace evaluation, must be a part of the program.

[FIGURE 1 OMITTED]

4. FURTHER PROGRESS

It is generally known, that if the theoretical presumptions aren't verified and debugged in praxis, they will lose its contribution. For this purpose it is inevitable to verify the created methodology on practical examples in the industrial companies. The cooperation and the possibility to verify the methodology is now ensured in two industrial companies in Pilsner region. Both of these companies form part of the SKODA HOLDING Inc. that is associating subsidiaries from a heavy machinery branch. The first company is SKODA ELECTRIC Inc., which is a world leading manufacturer of traction electrical sources and motors for trolley busses, trams, locomotives, metros and mining vehicles. The second company is SKODA TRANSPORTATION Inc., which is significant manufacturer and supplier of rail vehicles for railways and urban mass transportation (***, 2009).

These two companies are suitable representatives of industrial sphere in Pilsner region. It is highly possible that more companies, which will demonstrate interest in cooperation on the project and utilization of its results, will be used for methodology verification.

The work on presented methodology is still in progress. The final version of the algorithm as well as the knowledge rule base will be available in October 2009. After that the phase of verification will begin at least in two industrial companies mentioned in the paper before. I presume that the complete and final version of the whole work will be available at the turn of the year 2009.

5. CONCLUSION

In this paper I tried to explain the main ideas and principles of the new ergonomics methodology for design and evaluation of workplaces in industrial companies. The companies are slowly beginning to realize that ergonomics isn't only a tool for absolute perfection, but also a tool that ensures more effective production and better competitive advantage. As most of the companies don't possess the real ergonomic experts, so solving the ergonomic problems is quite difficult and that's why the use of my new methodology will come handy. Described methodology will help not only ergonomists in praxis but also it will serve as a complex system for development of single parts of an ergonomic science.

6. ACKNOWLEDGEMENT

This paper was created with the subsidy of the project 402/08/H051 under the Grant Academy of the Czech Republic. The name of this project is "Optimization of multidisciplinary design and modelling of virtual firm's production systems".

7. REFERENCES

Hlavenka, B. (1995). Rationalization of technological proceses, PC-DIR s.r.o., ISBN 80-214-0705-0, Brno

Chundela, L. (1993). Ergonomic, CVUT, ISBN 80-01-00327-2, Prague

Kral, M. (2002). Five steps of chronological process of ergonomic investigation and evaluation within the frame of production system, VUBP, Prague

Matousek, O. & Zastavka, Z. (1977). Analyzing and evaluating methods of the man-- machine system, SNTL, Prague

REFA (1991). Grundlagen der Arbeitsgestaltung, RefaMethodenlehre der Betriebsorganisation, Hanser, Munchen

*** (2009) http://www.skoda.cz--oficial pages of SKODA HOLDING Inc., Accessed on: 2009-04-24