ALBERT

Description: The optimization of production processes has always been one of the cornerstones for manufacturing companies, aimed to increase their productivity, minimizing the related costs. In the Industry 4.0 era, some innovative technologies, perceived as far away until a few years ago, have become reachable by everyone. The massive introduction of these technologies directly in the factories allows interconnecting the resources (machines and humans) and the entire production chain to be kept under control, thanks to the collection and the analyses of real production data, supporting the decision making process. This article aims to propose a methodological framework that, thanks to the use of Industrial Internet of Things—IoT devices, in particular the wearable sensors, and simulation tools, supports the analyses of production line performance parameters, by considering both experimental and numerical data, allowing a continuous monitoring of the line balancing and performance at varying of the production demand. A case study, regarding a manual task of a real manufacturing production line, is presented to demonstrate the applicability and the effectiveness of the proposed procedure.

Description: The aging issue in the work context is becoming a significant element of the future sustainability of service and industrial companies. It is well known that with increasing worker age the problem of maintaining the performance and the safety level when fatigue increases is a crucial point, and fatigue increases with the age. Due to social and political developments, especially in Western countries, the retirement age is increasing and companies operate with a higher workforce mean age. Therefore, the problem of recognizing and measuring fatigue has become a key aspect in the management of aging. Note that in the scientific engineering field, the problem of fatigue evaluation when a worker is performing his/her work activities is an important issue in the industrial and service world and especially in the context of the researchers that are investigating the human reliability assessment. As it is clear from the literature, the industrial operations management are suffering from some misleading concepts that only the medicine scientific context can clarify. Therefore, the aim of this paper is to define what are the open issues and the misleading concepts present in the classical fatigue evaluation methods, and second to define two experimental curves of fatigue that will help the decision makers to minimize the impact of fatigue on the workers, thus maximizing the sustainability of the working tasks assigned. This aim is achieved by examining the medical literature about the measurement of a particular kind of fatigue related to the circadian cycle, i.e., the cognitive one; after that, a survey about the possible technologies for measurements is performed. On the basis of technology selection, an experiment on real work activities is performed and some remarkable results about the fatigue in the workers observed and the technology use and its limitations are defined.

Description: In current industrial systems, automation is a very important aspect for assessing manufacturing production performance related to working times, accuracy of operations and quality. In particular, the introduction of a robotic system in the working area should guarantee some improvements, such as risks reduction for human operators, better quality results and a speed increase for production processes. In this context, human action remains still necessary to carry out part of the subtasks, as in the case of composites assembly processes. This study aims at presenting a case study regarding the reorganization of the working activity carried out in workstation in which a composite fuselage panel is assembled in order to demonstrate, by means of simulation tool, that some of the advantages previously listed can be achieved also in aerospace industry. In particular, an entire working process for composite fuselage panel assembling will be simulated and analyzed in order to demonstrate and verify the applicability and effectiveness of human–robot interaction (HRI), focusing on working times and ergonomics and respecting the constraints imposed by standards ISO 10218 and ISO TS 15066. Results show the effectiveness of HRI both in terms of assembly performance, by reducing working times and ergonomics—for which the simulation provides a very low risk index.

Description: Within the era of smart factories, concerning the ergonomics related to production processes, the Digital Twin (DT) is the key to set up novel models for monitoring the performance of manual work activities, which are able to provide results in near real time and to support the decision-making process for improving the working conditions. This paper aims to propose a methodological framework that, by implementing a human DT, and supports the monitoring and the decision making regarding the ergonomics performances of manual production lines. A case study, carried out in a laboratory, is presented for demonstrating the applicability and the effectiveness of the proposed framework. The results show how it is possible to identify the operational issues of a manual workstation and how it is possible to propose and test improving solutions.

Description: Aircrafts are responsible for a significant environmental impact mainly due to the air pollution caused by their motors. The use of composite materials for their production is a way to significantly reduce the weight of the structures and to maximise the ratio between the payload weight and the gasoline consumption. Moreover, the design phase has to consider the cost of different operations performed during the aircraft service life. During the entire life cycle, one of the main costs is the maintenance one. In the current literature, there is a lack of knowledge of methods for maintenance cost estimation in the aircraft industry; moreover, very few environmental assessment methods have been developed. Thus, the aim of this paper is to define a new method to support the aircraft design process; both the environmental and the economic dimensions have been included with the purpose of assessing the aircraft sustainability during its service life. A green index has been identified mixing the maintenance cost and an environmental parameter with the aim of identifying the greenest solution. A final practical application shows the feasibility and the simple application of the proposed approach.