Worker-centered evaluation and redesign of manufacturing tasks for ergonomics improvement using axiomatic design principles

Humans are considered the most valuable resource in manufacturing systems thanks to their craftsmanship, dexterity, and autonomy significantly affecting productivity, quality, and the overall company competitiveness. This paper introduces the SAGE (Systematic Approach to Generating Ergonomic Manufacturing tasks) methodology, a structured approach based on Axiomatic Design principles to integrate Human Factors evaluation early in the operations design phase and redesign manufacturing tasks to improve operators well-being. The primary objective is to mitigate discomfort and safety risks that often lead to musculoskeletal disorders, absenteeism, and production delays. SAGE provides a comprehensive framework for assessing ergonomic aspects of manufacturing tasks and identifying the need for redesign. It offers a detailed set of Functional Requirements (FRs) for reference, assesses FR satisfaction, evaluates task complexity using the Independence Axiom, and examines the intensity of FR satisfaction through the Information Axiom. The methodology includes specific implementation guidelines, ensuring its applicability across diverse manufacturing contexts. Its effectiveness is demonstrated through a large-scale parts assembly case study inspired by the bus and coach industrial sector, where a production engineer evaluated a windows assembly task and identified ergonomic design interventions. A comparative analysis with other relevant methods is finally presented, highlighting the approach's effectiveness.