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Abstract
In this research, digital human modeling (DHM) technology was utilized to model and analyze the ergonomic risk factors associated with the operation of a manual filling station in an automated medicine dispensing system. DHM not only helps in identifying and quantifying the risk factors associated with each manual task, but also assesses and evaluates various redesigning recommendations from a 'lean ergonomics' perspective. Lean ergonomics focus on reducing harmful/wasteful and unnecessary operator's motions and tasks. The implementation of lean ergonomics programs in businesses results in significant reductions in accidents, injuries, and other health-care related costs with relatively small investments. After a comprehensive data collection and a detailed task analysis, DHM was used to investigate and quantify the impact of various ergonomic interventions or design changes. Those interventions will not only reduce costs associated with occupational injuries, but also reduce absenteeism and increase productivity and workers' morale. The digital human simulation results showed that the design changes proposed reduced the strain on the operator's lower back and upper limbs muscles. Furthermore, the modified design enables operators of various anthropometric characteristics (5th percentile female to 95th percentile male) to operate the workstation with minimal effort, which helps in meeting customer requirements.
Keywords
Digital human modeling, manual filling station, ergonomic assessments, lean-ergonomics
1. Introduction
Ergonomics is one of the important factors in designing a new workstation in a production line or improving an existing one. Recently, ergonomics has been recognized to harmonize production systems from the very early stages in systems design. A combination of humans and automation in production systems provides us with flexibility, accuracy, and speed, which helps in ensuring quality production. On the other hand, simultaneous use of these two complementary elements brings up difficulties wherever there is a lack in the system design to match these elements properly [1].
In addition to ergonomics, implementing lean principles to manual operations in workstation (re)design suggests applying the changes that have the greatest improvement impact. In this study, a manual filling station in an automated pharmaceutical dispensing system is investigated. The manual filling station is placed next to a conveyer line and consists of a working table, a monitor through which filling information is accessible, a scanner, a printer to print labels, and medication shelves in...