Analyzing resilient performance of workers with multiple disturbances in production systems

With the emergence of Industry 5.0 and an increasing focus on human-centric approaches in manufacturing, the analysis of workers in production systems has gathered significant interest among researchers and practitioners. Previous studies have explored the impact of various aspects, such as skills, fatigue, and circadian rhythms, on human performance. However, the cumulative effect of these aspects as disturbances on work performance has yet to be fully elucidated. This study introduces an approach using the Functional Resonance Analysis Method (FRAM) to investigate the impact of multiple disturbances on workers’ performance. Furthermore, this approach explored how the resilience-related skill aspects of workers affect their performance under multiple disturbances. A case study on engine test and repair processes was conducted, employing qualitative data collection and semi-quantitative simulation studies examining the impact of combined disturbances across 4,094 scenarios. The results show that a larger number of compounded variabilities expressed in Common Performance Conditions (CPCs) made it significantly challenging to recover work performance, and CPCs with particularly critical effects were identified. In addition, the FRAM model of skilled workers was shown to sustain higher performance across more scenarios. The approach of this study has demonstrated its ability to provide insights for effectively and safely managing production systems while considering complex disturbances.