Common Automation Process System and Ergonomics Research study -CASPER

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Common Automation Process System and Ergonomics
Research study -CASPER
Project AFM212Br, completed by INBIS,
Loughborough University (Ergonomics and Safety
Research Institute),and University of
Salford September 2003 April 2004
Patrick Williams MSc, MRAeS, MCMI Casper
Project Manager, INBIS
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CASPER

• Introduction
• The Casper programme was defined between INBIS
  and Marks and Spencer following the success of
  the ASAP AFM 173 RD programme, and concerns with
  ergonomic issues in the food assembly sector.
• Developed in to AFM212Br with DEFRA.
• Objectives
• To consider whether more common automation
  techniques can be applied across a wider area of
  the food production/assembly sector
• Complete a limited Evaluation of the ergonomics
  issues in food production/assembly operations and
  consider the implication for the sector

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CASPER

• Supply chain
• Marks and Spencer identified the following
  organisations where maximum benefits may be
  possible
• Gunstones Bakery and filled roll production
• RHM Avana Cake decoration
• Tulip Meat slicing
• Uniq PFF - Salmon processing
• Deliverables
• Individual company assessment reports for use
  within the companies.
• Report on ergonomics issues in the sector, and
  common automation opportunities, and a proposal
  for progressing these.

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CASPER

• Analysis
• Two distinct analysis processes
• Automation
• Evaluation of current processes,
• Assessment automation techniques currently
  available,
• Assessment against new technology,
• Consideration of operational scope of
  robotics/mechatronics,
• Process assessment using Lean Thinking 5S
  methods (Automotive/Aerospace industry), for more
  effective and efficient operations.

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CASPER

• Ergonomics
• Observation/video of worker motions and
  evaluation using Rapid Upper Limb Assessment
  (RULA) (McAtamney and Corlett, 1992 and 1993)
  techniques, for physical strain and discomfort,
  and impact due to repetitive motion.
• Reach, and height dimensional assessment against
  ergonomic standards
• Interviews providing supporting evidence on
  physical comfort,
• and non physical aspects of repetitive work,
  
• Assessment of worker and management interaction
  in the design of processes.
• HS perspective and formal records for Work
  Related Upper Limb Disorders (WRULDs).

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CASPER

• Findings - roles
• Differing product lines, but various common
  themes in operation.
• High manual content in 3 of the lines assessed
  out of the 4.
• Various types of manual function
• Skilled critical part of the production process,
  cannot be replaced by automation without an
  impact on yield, long training periods to acquire
  skills and speed required.
• Skilled hand crafting within a production
  process environment perceived as added value
  carrying hand made branding.
• Multi skilled workers operating in various lower
  value roles either similar or dissimilar across
  various production processes within a single
  plant.
• Workers undertaking low value roles on production
  lines
• with limited rotation.

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CASPER
Findings ergonomics RULA scores across all
the observed production line tasks ranged from
3, requiring further investigation to 6/7 (out of
10), (requiring further investigation and
changes to be made soon). These scores equated
to the majority of tasks presenting low to
medium levels of risk, but with specific cases
requiring action. Common tasks that were
observed in all participating companies
were pick, place, inspection and packaging type
tasks. Across all companies these engaged
similar physical actions.
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CASPER
Findings ergonomics
A large majority of tasks observed as part of
this study, resulted in workers adopting poor
neck postures (flexed gt25 degrees) which were
sustained for prolonged periods of time. These
tasks were predominantly tasks requiring
inspection or placement of product components
onto the Lines.
Excessive reaching and twisting was often
observed throughout tasks conducted on all
participating production lines, these actions
were typically conducted frequently at high
rates of repetition. Excessive reaching and
twisting typically resulted from poor placement
of the product on the conveyor in relation to the
worker, i.e. outside recommended reach distance.
This was often determined by the output mechanism
of previous automated process machinery or from
trays of additional material being positioned
off to the side of the conveyor. Hence process
interaction is a critical aspect.
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CASPER
Findings ergonomics
Evidence suggests that work cycle times shorter
than 30 seconds, or cycles where more than 50
of the cycle time is involved in the same kind
of motion pattern, are strongly related to
disorders of the forearm and wrist (Silverstein
et al 1986). Cycle times observed on the
participating lines ranged from 1.3 to 46
seconds
In total 49 production line workers completed
a questionnaire. 25 -30 of workers questioned
had some form of ache, pain or discomfort that
they attributed to their work activities
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CASPER
Conclusions - Ergonomics
Based upon the scope of this assessment ergonomic
issues do exist in the Workplace. Some
consideration is given to this, but probably not
enough. Means of improving this are

• Greater human centred focus to activities in the
  workplace and
• interaction with Production machinery and
  processes.
• More job rotation, and multi skilling to allow
  flexibility in the plant, and variety of
  operation.
• Focus on processes and interaction between
  personnel and machines to reduce reach and
  stretching, to reduce posture problems, and
  lifting heavier objects.
• Conveyor and working surfaces at more optimum
  heights for workers, where safe allow adjustable
  workstations, and seating.
• Involve employees more in the on going processes
  associated with workplace Design and
  improvements.

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CASPER

• i.e Improved job design by consideration and
  analysis in the job
• definition process alongside the production
  process.
• Methods to achieve this are
• Evaluation of workload demands
• Task simulation
• Assessment of Physical actions required and rate
  of repetition
• Analyse recovery actions when system malfunctions
• Consider social interaction, personal workspace
  and worker self esteem
• More workforce involvement

       

• Recognise metrics associated with employee
  comfort in the workplace more, as part of the
  business case for change, it is a significant
  hidden cost in both the short and potentially
  long term.

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CASPER
Findings - Automation
Presentation of the food products for automation
needs to be addressed further. Previous
experience in other industries suggests that
initially this can be done with little/no cost
and the better layout in terms of position and
orientation improve the efficiency and
consistency of the overall handling process for
automation to be successful it is essential that
the basic principles of orientation and
positioning be developed as core line
procedures. Vision, alignment and manipulator
systems are applied, but need to be more
appropriate, and priced for the industry.
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CASPER
Findings - Automation

• Products can be categorised in to rigid and non
  rigid forms, e.g
• Unpacked ham is non rigid, rigid - bread rolls,
  or some packed products.
• Automation of rigid products can apply technology
  transfer
• using other recognised techniques.
• Non rigid products are more difficult to automate
  because of
• lack of databases of experience, and need for
  newer technology
• to handle more complex products and variability.
• The roles identified within CASPER are in many
  cases relatively simple, and hence may be
  achieved by automation particularly where skill
  and value associated is low.
• Cycle times (1-3 sec), position, orientation and
  accuracy requirements are well within the grasp
  of automation technology.
• But cost, materials and reliability are critical
  issues
• for acceptance

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CASPER
Conclusions - Automation

• With many pick and place type roles automation
  can be applied
• as a means of making efficiencies. This is a
  common theme within the companies assessed, and
  need not result in overly complex manipulation
  requirements.
• A cost effective automation/mechatronic approach
  could have significant benefits
• A system with a target cost of up to 15,000
  could open up a new market, for the food and
  other sectors requiring light weight reliable
  systems
• The new technology focussing on
• rapid change of function
• control by non skilled workers,
• ability to rapidly align within the production
  process
• are the key enabling technologies.
• Rapid change end effectors to support various
  functions

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CASPER
Outline specification for a suite of modular
units.      Number of Axes 4        
Reach 1m         Payload 1 2 Kg
(including end effector)         Speed 1m/s
Accuracy /- 1mm System will need to be
mobile, and easily located on to set positions on
the production line, where it can align itself
with the production process and position of
produce. The system will be designed for
hygiene, environment and lubrication requirements
that are applicable in the food
industry. Plastics will be used where
appropriate to reduce weight and cost, and the
design Will Consider minimising the number of
mouldings etc. Programming is a major
consideration, and Salford's Virtual teach
using sensor glove techniques are proposed, as
a means of enabling Programming and rapid
interchangeability of the unit.
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CASPER

• Phased technology development approaches
• An assessment phase to capture the specification
  requirements,
• Simulation work to initiate the design process
  based upon the
• motions required against product types.
• Research on the simple programming system for the
  robot,
• functions to be performed
• Selection in the workplace to make the system
  moveable across functions
• Integration with vision systems for location and
  control purposes,
• Man machine interface (ergonomics) and safety
• Detailed design and development,
• Works and site trials of prototype hardware.  

Further work is required with potential partners
to develop the approach In to an RD programme
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CASPER

• Overall conclusion.
• The sector needs to consider ergonomic based
  metrics alongside
• cost metrics within the planning and operations
  of the production
• Facility to a greater extent.
• The application of low cost automation against
  the range of common
• pick, place and pack functions needs to be
  researched further as
• a potential RD LINK project, providing
  affordable solutions.

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CASPER

• Combining the conclusions from the common
  automation and
• Ergonomic studies generates two potential
  solutions to improve the sector
• Provision of improved company or use of third
  party evaluations within process and plant design
  covering
• Ergonomic evaluation
• Simulation of production process and human
  interaction
• Application of lean type techniques for layout
• Technology developments to support low cost
  automation solutions, plug and play, multi
  functional simply controlled units operating
  within plants covering the high repetition low
  value tasks.
• An outline specification has been created.

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CASPER

• For each participating company reports and
  recommendations were made on each evaluation to
  provide a local opportunity for change.
• Each company has been provided with the
  opportunity of progressing the outcomes within a
  LINK project to consider low cost automation
  solutions focussing on
• Lower value jobs
• Common or near common functions

• Creating potential multi company exploitation
  of common
• Technology programme.
• Considerable potential savings from direct
  costs of employment,
• improved efficiency, hidden costs from staff
  turnover and ergonomic
• Issues.

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CASPER
Way forward ..

• As a result of the work undertaken through
  CASPER -
• Integrated services for ergonomic and
  production process improvement
• are available from INBIS, Loughborough and
  Salford University.
• These can be applied to new design or
  improvement of the production
• facilities, and reduce ergonomic and safety
  related problems.
• The opportunity to develop a low cost automation
  solution remains, and
• needs to be opened to a wider market in the
  sector.