Workplace Optimisation Service LMS v0 · Workplace Optimization Service (WOS) Bergamo, 18 July 2018 8 WOS. Real-time Ergonomics Assessment Action level 1 A score of 1 or 2 indicates

Workplace Optimisation Service

T4.3 & T5.3

Homo et Machina: La simbiosi nell Industria 4.0

18 July, 2018

Laboratory for Manufacturing Systems and Automation (LMS)

Workplace Optimization Service (WOS)

Bergamo, 18 July 20182

❖ LMS is involved in a number of research projects funded by the CEU and

European industrial partners. Particular emphasis is given to the co-

operation with the European industry as well as with a number of "hi-

tech" firms

❖ LMS is organized in three different scientific groups:

! Manufacturing Processes Modelling and Energy Efficiency

! Robots, Automation and Virtual Reality in Manufacturing

! Manufacturing Systems

LMS. Who we are




LMS. Indicative RTD Collaborations




HUMAN. ConceptHUMAN aims at developing a platform that is contextually aware of both the factory and the human operator, identifying when an intervention is required in order to support the operator in performing their tasks with the desired quality, whilst ensuring their well-being. The preliminary analysis of needs yielded to five so called services, divided into two categories : Short Term Services and Long Term Services.

Exoskeleton Service KIT Service

WOSSII

SKN




WOS. A long term serviceHUMAN can trigger interventions to help human operator based in his status, but what if the system detects…

… frequently that operators are very tired in a specific area?

… a large percentage of sick leaves associated with a specific task?

… frequently that operators are confused when executing a task and request

instructions?

… …

Short term interventions are not addressing the problem " a long term intervention is needed to improve the workplace!




WOS. Immersive virtual shop floor environment• Immersive VE based on the COMAU shop

floor - Allows the visualization of shop floor and simulation of mfg tasks

• Interactions modelling - Enables humans to accurately manipulate scene objects using different grasp types.

• " Serve as a baseline for assessments

Power one hand grasp

Precise one hand grasp

Power two hand grasp




WOS. Enhanced Spaghetti Diagram▪ Simple but efficient lean tool for

optimizing handling of materials and movement of workers.

Up unt i l now performed by following operator around, using pen and paper!

▪ Automatic generation of the Spaghetti Diagram (tracking of the user’s movements)

▪ Heatmap feature to extract time information and detect bottlenecks & time waste




WOS. Real-time Ergonomics Assessment

Action level 1 A score of 1 or 2 indicates that posture is acceptable if it is not maintained or repeated for long periods. Action level 2 A score of 3 or 4 indicates that further investigation is needed and changes may be required. Action level 3 A score of 5 or 6 indicates that investigation and changes are required soon. Action level 4 A score of 7+ indicates that investigation and changes are required immediately.

▪ Sensors track operator’s body - joint data

▪ Real time estimation of score for the current posture

▪ 1 x Kinect for Windows v2

Rapid Upper Limb Assessment - online scoring




WOS. Visibility – Reachability – Golden ZoneVisibility Assessment • Near and mid peripheral view • Highlight visible elements in

the immersive environment and the Engineer UI

Reachability Assessment • 50th percentile of American

males • Highlight grabbable elements

in the immersive environment and the Engineer UI

Golden Zone • To eliminate waste all activities

have to remain inside the GZ • Highlight GZ in the immersive

environment and the Engineer UI




WOS. Layout Redesign

▪ Pop up information notifications of layout elements

▪ Information retrieved by the HUMAN system

▪ Real time estimation of the impact of the rearrangement workplace

▪ Use of A* path finding algorithm for distance estimation

▪ Modification of the layout from the immersive environment

▪ Shadow casting when moving a 3D element




WOS. Relevant Papers▪ Workplace analysis and design using virtual reality techniques. Michalos, G., Karvouniari, A., Dimitropoulos, N., Togias, T. and Makris, S., 2018. CIRP Annals.

▪ Exoskeleton integration in manufacturing lines using Virtual Reality techniques. Michalos, G., Karvouniari, A., Dimitropoulos, and Makris, S., 2018. CIRPe.

▪ Chryssolouris, G., 2013, Manufacturing systems: theory and practice, Springer Science & Business Media.

▪ An intelligent search algorithm-based method to derive assembly line design alternatives, Michalos G., Makris S. and Mourtzis D., 2012, International Journal of Computer Integrated Manufacturing, 25/3:211-229.

▪ Semantic-based taxonomy for immersive product design using VR techniques, S. Makris, L. Rentzos, G. Pintzos, D. Mavrikios, G. Chryssolouris, 2012, CIRP Annals - Manufacturing Technology, 61/1:147–150.

▪ A Web and Virtual Reality-based Platform for Collaborative Product Review and Customisation,Chryssolouris G., Mavrikios D., Pappas M., Xanthakis E., Smparounis K., 2009, In: Wang L., Nee A.(eds) Collaborative Design and Planning for Digital Manufacturing, Springer, London.

▪ Simulation in manufacturing: review and challenges, Mourtzis, D., Doukas, M. and Bernidaki, D., 2014, Procedia CIRP, 25:213-229.

Thank you!

This project has received funding from the European

Union’s Horizon 2020 research and innovation programme under grant agreement no. 723737

For more information visit us at http://www.humanmanufacturing.eu/

Documents

Workplace Optimisation Service LMS v0 · Workplace Optimization Service (WOS) Bergamo, 18 July 2018 8 WOS. Real-time Ergonomics Assessment Action level 1 A score of 1 or 2 indicates