Assigning rest times to workers in assembly lines with ergonomically hazardous tasks: an approach to defend companies' profitability

In the context of assembly lines, the term 'rest time' refers to those time of inactivity allowed to a worker after the completion of his/her tasks on a product. Rest times are often assigned to workers that perform ergonomically hazardous tasks, to prevent their occupational diseases. When rest times are assigned after balancing the line, the line becomes unbalanced and the ergonomic load of workers is reduced at the price of deteriorated line performance. In this paper, an approach able to assign rest times during the balancing procedure is presented. The approach consists of a genetic algorithm coupled with a discrete event simulator to evaluate the fitness function of individuals, which considers the performance, the ergonomic, and the cost aspects. The OCRA index has been utilised to assess the ergonomic risk of workers. Results show that the presented approach can significantly support firms in designing manual assembly lines: the possibility to assign rest times during the balancing procedure allows for increasing the quality of solutions in 103 out of 135 benchmark instances. The greatest improvements are obtained when the ergonomic load of tasks is relevant, by achieving good performances of the line with limited costs, thus defending companies' profitability.

Automated summary

In the context of assembly lines, rest times refer to the allowed inactivity period after workers complete their tasks. Rest times are assigned to prevent occupational diseases, but can affect the line's performance. This paper presents an approach using a genetic algorithm and a discrete event simulator to assign rest times during the balancing procedure, considering performance, ergonomic aspects, and costs. Results show that this approach significantly improves the quality of solutions for manual assembly lines, particularly when tasks have high ergonomic load, maintaining line performance while minimizing costs and protecting companies' profitability.