Ergonomics & Workplace Design: application of ERGO-UAS System in FIAT group automobiles, Vitello M. ET AL. (2013)

Ergo-UAS industrialization: management of a massive amount of data to integrate ergonomics into product design and production processes. Since 2007 Fiat Group Automobiles adopted UAS method to assign a basic time to execute a motion of an activity described on process sheets where production cycles are structured and measured with a standard and universal system (MTM-UAS, Methods-Time Measurement). Furthermore, FGA has introduced an ergonomic method, EAWS, to calculate, for each work-station, the proper biomechanical load. The previous system, to set standard time applied a relatively constant allowance to each single motion (about 4÷6%), as a function of body postures and forces.
Ergo-UAS system connects UAS with EAWS because to feed EAWS method is necessary to input a lot of ergonomic parameters (postures, forces, actions and grip, material manual handling, trolley pushing and pulling) directly on each row of UAS analysis. By the overall working tasks assignment to a work-station (line balancing), Ergo-UAS aims at controlling and limiting the work-load within the compliance ranges set by ISO/CEN standard. Ergo-UAS determines an ergonomic allowance factor, which, added to the total basic time (UAS time) gives the so called standard time. The Ergo-UAS model ranges from a minimum allowance of 1% to a maximum theoretical value of 52%. For workstation under control and well-designed the maximum allowance value is 13,5%.
The core challenges during Ergo-UAS implementation and management are:

– Magnitude of data: UAS analysis, ergo characterizations, Fiat data-blocks, product validities, work cycles, production program (mix of production)

– Speed and frequency of change (business dynamic condition)

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