Innovation and employee injury risk in automotive disassembly operations

International Journal of Production Research

Volumn 56, Issue 9, 2018, Pages 3188-3203

  Neumann, W Patrick ^a   Winkel, Jörgen ^b,c   Palmerud, Gunnar ^b   Forsman, Mikael ^d,e  

^a RYERSON UNIVERSITY   (Canada)

^b UNIVERSITY OF GOTHENBURG   (Sweden)

^c TECHNICAL UNIVERSITY OF DENMARK   (Denmark)

^d KAROLINSKA INSTITUTE   (Sweden)

^e UNIVERSITY OF GÄVLE   (Sweden)

Author keywords

back track factory; corporate social sustainability; engineering design; ergonomics; human factors; manufacturing; physical workload; rationalisation

Indexed keywords

ERGONOMICS; HAZARDS; HEALTH RISKS; HUMAN ENGINEERING; HUMAN RESOURCE MANAGEMENT; JOB ANALYSIS; MANUFACTURE; RISK ASSESSMENT; SUSTAINABLE DEVELOPMENT;

BACK TRACK; ENGINEERING DESIGN; PHYSICAL WORKLOADS; RATIONALISATION; SOCIAL SUSTAINABILITY;

ENGINEERING RESEARCH;

EID: 85042937746     PISSN: 00207543     EISSN: 1366588X     Source Type: Journal    
DOI: 10.1080/00207543.2018.1432910     Document Type: Article

References (80)

1. Badham, R., and P., Ehn. 2000. “Tinkering with Technology: Human Factors, Work Redesign, and Professionals in Workplace Innovation.” Human Factors and Ergonomics in Manufacturing and Service Industries 10 (1): 61–82.10.1002/(ISSN)1520-6564
2. Bainbridge, L., 1983. “Ironies of Automation.” Automatica 19: 775–779.10.1016/0005-1098(83)90046-8
3. Battini, D., X., Delorme, A., Dolgui, A., Persona, and F., Sgarbossa. 2016. “Ergonomics in Assembly Line Balancing Based on Energy Expenditure: A Multi-Objective Model.” International Journal of Production Research 54 (3): 824–845. doi:10.1080/00207543.2015.1074299.
4. Broberg, O., 2007. “Integrating Ergonomics into Engineering: Empirical Evidence and Implications for Ergonomists.” Human Factors and Ergonomics in Manufacturing 17: 353–366.10.1002/(ISSN)1520-6564
5. Bruce, R. A., L. D., Fisher, M. N., Cooper, and G. O., Gey. 1974. “Separation of Effects of Cardiovascular Disease and Age on Ventricular Function with Maximal Exercise.” The American Journal of Cardiology 34 (7): 757–763.10.1016/0002-9149(74)90692-4
6. Carter, B., A., Danford, D., Howcroft, H., Richardson, A., Smith, and P., Taylor. 2013. “‘Stressed out of My Box’: Employee Experience of Lean Working and Occupational Ill-Health in Clerical Work in the UK Public Sector.” Work, Employment and Society 27: 747–767.10.1177/0950017012469064
7. Clegg, C. W., 2000. “Sociotechnical Principles for System Design.” Applied Ergonomics 31: 463–477.10.1016/S0003-6870(00)00009-0
8. Dabhilkar, M., and P., Åhlström. 2013. “Converging Production Models: The STS versus Lean Production Debate Revisited.” International Journal of Operations and Production Management 33: 3–3.
9. Docherty, P., J., Forslin, and A. B., (Rami) Shani. 2002. Creating Sustainable Work Systems. London: Routledge.
10. Dul, J., and W. P., Neumann. 2009. “Ergonomics Contributions to Company Strategies.” Applied Ergonomics 40: 745–752.10.1016/j.apergo.2008.07.001
11. Eijnatten, F. M. v., U. d., Sitter, B., Gustavsen, F., Emery, H. v., Beinum. 1993. The Paradigm That Changed the Work Place. Stockholm: Van Gorcum, Arbetslivscentrum.
12. Erdinç, O., and P. H. P., Yeow. 2011. “Proving External Validity of Ergonomics and Quality Relationship through Review of Real-World Case Studies.” International Journal of Production Research 49 (4): 949–962.10.1080/00207540903555502
13. EU, the European Parliament and the Council on end-of-life vehicles. 2000. Directive on End-of-Life Vehicles 2000/53/EC.
14. Finnsgård, C., C., Wänström, L., Medbo, and W. P., Neumann. 2011. “Impact of Materials Exposure on Assembly Workstation Performance.” International Journal of Production Research 49: 7253–7274.10.1080/00207543.2010.503202
15. Genaidy, A., W., Karwowski, and C., Shoaf. 2002. “The Fundamentals of Work System Compatibility Theory: An Integrated Approach to Optimize Human Performance at Work.” Theoretical Issues in Ergonomics Science 3 (4): 346–368. 46.10.1080/14639220210124076
16. Giri, R., and M., Kanthababu. 2015. “Generating Complete Disassembly Sequences by Utilising Two-Dimensional Views.” International Journal of Production Research 53 (17): 5118–5138. doi:10.1080/00207543.2015.1005249.
17. Glock, C. H., E. H., Grosse, W. P., Neumann, and F., Sgarbossa. 2017. “Editorial: Human Factors in Industrial and Logistic System Design.” Computers and Industrial Engineering. 111 (Supplement C): 463–466.10.1016/j.cie.2017.08.014
18. Goggins, R. W., P., Spielholz, and G. L., Nothstein. 2008. “Estimating the Effectiveness of Ergonomics Interventions through Case Studies: Implications for Predictive Cost-Benefit Analysis.” Journal of Safety Research 39: 339–344.10.1016/j.jsr.2007.12.006
19. Grosse, E. H., C. H., Glock, M. Y., Jaber, and W. P., Neumann. 2015. “Incorporating Human Factors in Order Picking Planning Models: Framework and Research Opportunities.” International Journal of Production Research 53 (3): 695–717. doi:10.1080/00207543.2014.919424.
20. Güngör, A., and S. M., Gupta. 2002. “Disassembly Line in Product Recovery.” International Journal of Production Research 40 (11): 2569–2589. doi:10.1080/00207540210135622.
21. Hansson, G.-Å., I., Balogh, K., Ohlsson, L., Rylander, and S., Skerfving. 1996. “Goniometer Measurement and Computer Analysis of Wrist Angles and Movements Applied to Occupational Repetitive Work.” Journal of Electromyography and Kinesiology 6 (1): 23–35.10.1016/1050-6411(95)00017-8
22. Hansson, G.-Å., P., Asterland, N.-G., Holmer, and S., Skerfving. 2001. “Validity and Reliability of Triaxial Accelerometers for Inclinometry in Posture Analysis.” Medical and Biological Engineering and Computing 39 (4): 405–413.10.1007/BF02345361
23. Hansson, G.-Å., I., Arvidsson, K., Ohlsson, C., Nordander, S. E., Mathiassen, S., Skerfving, and I., Balogh. 2006. “Precision of Measurement of Physical Workload during Standardized Manual Handling. Part II: Inclinometry of Head, Upper Back, Neck and Upper Arms.” Journal of Electromyography and Kinesiology 16 (2): 125–136.10.1016/j.jelekin.2005.06.009
24. Hasle, P., 2014. “Lean Production-an Evaluation of the Possibilities for an Employee Supportive Lean Practice.” Human Factors and Ergonomics in Manufacturing and Service Industries 24: 40–53.10.1002/hfm.v24.1
25. Hasle, P., A., Bojesen, P. L., Jensen, and P., Bramming. 2012. “Lean and the Working Environment: A Review of the Literature.” International Journal of Operations & Production Management 32: 829–849.10.1108/01443571211250103
26. Helander, M., and M., Nagamachi. 1992. Design for Manufacturability: A Systems Approach to Concurrent Engineering and Ergonomics. London: Taylor and Francis.
27. Jin, J. B., C. S., Leem, and C. H., Lee. 2016. “Research Issues and Trends in Industrial Productivity over 44 Years.” International Journal of Production Research 54 (5): 1273–1284. doi:10.1080/00207543.2015.1064181.
28. Johansson, J., and L., Abrahamsson. 2009. “The Good Work–A Swedish Trade Union Vision in the Shadow of Lean Production.” Applied Ergonomics 40 (4): 775–780.10.1016/j.apergo.2008.08.001
29. Johansson, J. Å., R., Kadefors, S., Rubenowitz, U., Klingenstierna, I., Lindström, T., Engström, and M., Jahansson. 1993. “Musculoskeletal Symptoms, Ergonomic Aspects and Psychosocial Factors in Two Different Truck Assembly Concepts.” International Journal of Industrial Ergonomics 12 (1–2): 35–48. doi:10.1016/0169-8141(93)90036-D.
30. Jonker D., B., Rolander, I., Balogh, L., Sandsjö, K., Ekberg, and J., Winkel. 2011. “Mechanical Exposure Among General Practice Dentists in Sweden and Possible Implications of Rationalization.” Ergonomics 54 (10): 953–960. doi:10.1080/00140139.2011.606919.
31. Jonker D., B., Rolander, I., Balogh, L., Sandsjö, K., Ekberg, and J., Winkel. 2013. “Rationalisation in Public Dental Care–Impact on Clinical Work Tasks and Mechanical Exposure for Dentists–A Prospective Study.” Ergonomics 56 (2): 303–313. doi:10.1080/00140139.2012.760751.
32. Jonsson, B., 1982. “Measurement and Evaluation of Local Muscular Strain in the Shoulder during Constrained Work.” Journal of Human Ergology 11 (1): 73–88.
33. Kazmierczak, K., 2005. “Industrial Development of Car Disassembly–Ergonomics and System Performance.” PhD diss., Lund Institute of Technology and National Institute for Working Life. ISBN 91-628-6595-1, 52 pp.
34. Kazmierczak, K., J., Winkel, and R. H., Westgaard. 2004. “Car Disassembly and Ergonomics in Sweden: Current Situation and Future Perspectives in Light of New Environmental Legislation.” International Journal of Production Research 42 (7): 1305–1324.10.1080/00207540310001624393
35. Kazmierczak, K., S. E., Mathiassen, M., Forsman, and J., Winkel. 2005. “An Integrated Analysis of Ergonomics and Time Consumption in Swedish ‘Craft-Type’ Car Disassembly.” Applied Ergonomics 36 (3): 263–273.10.1016/j.apergo.2005.01.010
36. Kazmierczak, K., S. E., Mathiassen, W. P., Neumann, and J., Winkel. 2006. “Observer Reliability of Industrial Activity Analysis Based on Video Recordings.” International Journal Industrial Ergonomics 36 (3): 275–282.10.1016/j.ergon.2005.12.006
37. Kazmierczak, K., W. P., Neumann, and J., Winkel. 2007. “A Case Study of Serial-Flow Car Disassembly: Ergonomics, Productivity and Potential System Performance.” Human Factors and Ergonomics in Manufacturing 17: 331–351. doi:10.1002/hfm.20078.
38. Koukoulaki, T., 2014. “The Impact of Lean Production on Musculoskeletal and Psychosocial Risks: An Examination of Sociotechnical Trends over 20 Years.” Applied Ergonomics 45: 198–212.10.1016/j.apergo.2013.07.018
39. Lacerda, A. P., A. R., Xambre, and H. M., Alvelos. 2016. “Applying Value Stream Mapping to Eliminate Waste: A Case Study of an Original Equipment Manufacturer for the Automotive Industry.” International Journal of Production Research 54 (6): 1708–1720. doi:10.1080/00207543.2015.1055349.
40. Landsbergis, P. A., J., Cahill, and P., Schnall. 1999. “The Impact of Lean Production and Related New Systems of Work Organization on Worker Health.” Journal of Occupational Health Psychology 4: 108–130.10.1037/1076-8998.4.2.108
41. Leigh, J. P., 2011. “Economic Burden of Occupational Injury and Illness in the United States.” Milbank Quarterly 89: 728–772.10.1111/milq.2011.89.issue-4
42. Leigh, J. P., S. B., Markowitz, M., Fahs, C., Shin, and P. J., Landrigan. 1997. “Occupational Injury and Illness in the United States. Estimates of Costs, Morbidity, and Mortality.” Archives of Internal Medicine 157: 1557–1568.10.1001/archinte.1997.00440350063006
43. Liker, J. K., 2004. The Toyota Way: 14 Management Principles from the World’s Greatest Manufacturer. London: McGraw-Hill.
44. Melin, B., U., Lundberg, J., Söderlund, and M., Granqvist. 1999. “Psychological and Physiological Stress Reactions of Male and Female Assembly Workers: A Comparison between Two Different Forms of Work Organisation.” Journal of Organizational Behavior 20 (1): 47–61.10.1002/(ISSN)1099-1379
45. Näslund, D., 2008. “Lean, Six Sigma and Lean Sigma: Fads or Real Process Improvement Methods?” Business Process Management Journal 14 (3): 269–287.10.1108/14637150810876634
46. Neumann, W. P., and J., Dul. 2010. “Human Factors: Spanning the Gap between OM and HRM.” International Journal of Operations & Production Management 30: 923–950.10.1108/01443571011075056
47. Neumann, W. P., and L., Medbo. 2010. “Ergonomics and Productivity in Two Material Supply Concepts: Big Box Vs. Narrow Bins.” International Journal of Industrial Ergonomics 40 (5): 541–548.10.1016/j.ergon.2010.06.004
48. Neumann, W. P., and J., Village. 2012. “Ergonomics Action Research II: A Framework for Integrating HF into Work System Design.” Ergonomics 55: 1140–1156.10.1080/00140139.2012.706714
49. Neumann, W. P., M., Ekman, and J., Winkel. 2009. “Integrating Ergonomics into System Development - the Volvo Powertrain Case.” Applied Ergonomics 40 (3): 527–537. doi:10.1016/j.apergo.2008.09.010.
50. Neumann, W. P., S., Kihlberg, P., Medbo, S. E., Mathiassen, and J., Winkel. 2002. “A Case Study Evaluating the Ergonomic and Productivity Impacts of Partial Automation Strategies in the Electronics Industry.” International Journal of Production Research 40 (16): 4059–4075.10.1080/00207540210148862
51. Neumann, W. P., J., Winkel, L., Medbo, R., Magneberg, and S. E., Mathiassen. 2006. “Production System Design Elements Influencing Productivity and Ergonomics–a Case Study of Parallel and Serial Flow Strategies.” International Journal of Operations and Production Management 26 (8): 904–923.10.1108/01443570610678666
52. Nordander, C., K., Ohlsson, I., Åkesson, I., Arvidsson, I., Balogh, G.-Å., Hansson, U., Strömberg, R., Rittner, and S., Skerfving. 2013. “Exposure-Response Relationships in Work-Related Musculoskeletal Disorders in Elbows and Hands–A Synthesis of Group-Level Data on Exposure and Response Obtained Using Uniform Methods of Data Collection.” Applied Ergonomics 44 (2): 241–253.10.1016/j.apergo.2012.07.009
53. NRC (National Research Council). 2001. Musculoskeletal Disorders and the Workplace: Low Back and Upper Extremities. Washington, DC: National Academy Press.
54. Østensvik, T., K. B., Veiersted, P., Nilsen, E., Cuchet, J., Johansson Hanse, C., Carlzon, and J., Winkel. 2008. “A Search for Risk Factors of Upper Extremity Disorders among Forest Machine Operators in France and Norway.” International Journal of Industrial Ergonomics 38 (11–12): 1017–1027. doi:10.1016/j.ergon.2008.01.016.
55. Paksoy, T., A., Güngör, E., Özceylan, and A., Hancilar. 2013. “Mixed Model Disassembly Line Balancing Problem with Fuzzy Goals.” International Journal of Production Research 51 (20): 6082–6096. doi:10.1080/00207543.2013.795251.
56. Palmerud, G., M., Forsman, W. P., Neumann, and J., Winkel. 2012. “Mechanical Exposure Implications of Rationalization: A Comparison of Two Flow Strategies in a Swedish Manufacturing Plant.” Applied Ergonomics 43 (6): 1110–1121.10.1016/j.apergo.2012.04.001
57. Punnett, L., and D. H., Wegman. 2004. “Work-Related Musculoskeletal Disorders: The Epidemiologic Evidence and the Debate.” Journal of Electromyography and Kinesiology 14 (1): 13–23.10.1016/j.jelekin.2003.09.015
58. Rose, L. M., U. E., Orrenius, and W. P., Neumann. 2013. “Work Environment and the Bottom Line: Survey of Tools Relating Work Environment to Business Results.” Human Factors and Ergonomics in Manufacturing and Service Industries 23 (5): 368–381.10.1002/hfm.v23.5
59. Selin, K., J., Winkel, and Stockholm MUSIC I study group. 1994. “Evaluation of Two Instruments for Recording Sitting and Standing Postures and Number of Foot Steps.” Applied Ergonomics 25 (1): 41–46.10.1016/0003-6870(94)90030-2
60. Shoaf, C., A., Genaidy, and W., Karwowski. 1998. “Comprehensive Manual Handling Limits for Lowering, Pushing, Pulling and Carrying Activities.” Occupational Health and Industrial Medicine 38 (2): 86.
61. Smith, A., 1776. The Wealth of Nations. London: Pelican Classics.
62. Sobhani, A., M. I. M., Wahab, and W. P., Neumann. 2015. “Investigating Work-Related Ill Health Effects in Optimizing the Performance of Manufacturing Systems.” European Journal of Operational Research 241: 708–718.10.1016/j.ejor.2014.09.032
63. Svendsen, S. W., J. B., Bonde, S. E., Mathiassen, K., Stengaard-Pedersen, and L. H., Frich. 2004. “Work Related Shoulder Disorders: Quantitative Exposure-Response Relation with Reference to Arm Posture.” Occupational and Environmental Medicine 61 (10): 844–853.10.1136/oem.2003.010637
64. Takala, E. P., I., Pehkonen, M., Forsman, G.-Å., Hansson, S. E., Mathiassen, W. P., Neumann, G., Sjøgaard, B., Veiersted, R., Westgaard, and J., Winkel. 2010. “Systematic Evaluation of Observational Methods Assessing Biomechanical Exposures at Work.” Scandinavian Journal of Work, Environment and Health 36: 3–24.10.5271/sjweh.2876
65. Takala, J., P., Hämäläinen, K. L., Saarela, L. Y., Yun, K., Manickam, T. W., Jin, P., Heng, et al. 2013. “Global Estimates of the Burden of Injury and Illness at Work in 2012.” Journal of Occupational and Environmental Hygiene 11: 326–337.
66. Thürer, M., I., Tomašević, and M., Stevenson. 2017. “On the Meaning of ‘Waste’: Review and Definition.” Production Planning and Control 28 (3): 244–255.10.1080/09537287.2016.1264640
67. Vermeulen, I., C., Block, J., Van Caneghem, W., Dewulf, S. K., Sikdar, and C., Vandecasteele. 2012. “Sustainability Assessment of Industrial Waste Treatment Processes: The Case of Automotive Shredder Residue.” Resources, Conservation and Recycling 69: 17–28.10.1016/j.resconrec.2012.08.010
68. Vézina, M., E., Cloutier, S., Stock, K., Lippel, and É., Fortin. 2011. Summary Report. Québec Survey on Working and Employment Conditions and Occupational Health and Safety (Eqcotesst). Institut national de santé publique du Québec and Institut de la statistique du Québec, Québec, p. 49. http://www.inspq.qc.ca/pdf/publications/1356_EnqQuebCondTravailEmpSanteSecTravail_VA.pdf
69. Village, J., M., Greig, S., Zolfaghari, F., Salustri, and W. P., Neumann. 2014. “Adapting Engineering Design Tools to Include Human Factors.” IIE Transactions on Occupational Ergonomics and Human Factors 2 (1): 1–14. doi:10.1080/21577323.2014.905884.
70. Wells, R., R., Norman, W. P., Neumann, D., Andrews, J., Frank, H., Shannon, and M., Kerr. 1997. “Assessment of Physical Work Load in Epidemiologic Studies: Common Measurement Metrics for Exposure Assessment.” Ergonomics 40 (1): 51–61.10.1080/001401397188369
71. Wells, R., S. E., Mathiassen, L., Medbo, and J., Winkel. 2007. “Time–A Key Issue for Musculoskeletal Health and Manufacturing.” Applied Ergonomics 38: 733–744.10.1016/j.apergo.2006.12.003
72. Westgaard, R., and J., Winkel. 2011. “Occupational Musculoskeletal and Mental Health: Significance of Rationalization and Opportunities to Create Sustainable Production Systems–A Systematic Review.” Applied Ergonomics 42: 261–296.10.1016/j.apergo.2010.07.002
73. Wild, R., 1995. Production and Operations Management. London: Thomson Learning.
74. Williams, K., C., Haslam, J., Williams, T., Cutler, A., Adcroft, and S., Johal. 1992. “Against Lean Production.” Economy and Society 21: 320–354.
75. Winkel, J., and S. E., Mathiassen. 1994. “Assessment of Physical Work Load in Epidemiologic Studies: Concepts, Issues and Operational Considerations.” Ergonomics 37 (6): 979–988.10.1080/00140139408963711
76. Winkel, J., and R. H., Westgaard. 1996. “Editorial: A Model for Solving Work Related Musculoskeletal Problems in a Profitable Way.” Applied Ergonomics 27: 71–77.10.1016/0003-6870(95)00061-5
77. Winkel, J., K., Edwards, B. D., Birgisdóttir, and S., Gunnarsdóttir. 2015. “Facilitating and Inhibiting Factors in Change Processes Based on the Lean Tool ‘Value Stream Mapping’: An Exploratory Case Study at Hospital Wards.” International Journal of Human Factors and Ergonomics 3 (3/4): 291–302.
78. Winkel, J., B., Schiller, L., Dellve, K., Edwards, W. P., Neumann, T., Öhrling, and R. H., Westgaard. 2017, August 20–23. “Scientific Evidence Suggests a Changed Approach in Ergonomic Intervention Research. The Nordic Ergonomics and Human Factors Society (NES). Lund.” In Conference Proceedings, ‘Joy at Work’, edited by A.-L., Osvalder, M., Blomé, and H., Bodnar, 430–436. Lund: Lund University. ISBN 978-91-7753-152-4.
79. Yin, R. K., 1994. Case Study Research–Design and Methods. 2nd ed. Vol. 5. London: Sage.
80. Zare, M., M., Croq, F., Hossein-Arabi, R., Brunet, and Y., Roquelaure. 2015. “Does Ergonomics Improve Product Quality and Reduce Costs? A Review Article.” Human Factors and Ergonomics in Manufacturing and Service Industries 26 (2): 205–223. doi:10.1002/hfm.20623.