Modeling and qualification of future digitalized assembly work

Abstract

In recent years, the utilization of smart wearables has gained prominence in various industries, promising enhanced productivity and ergonomic benefits. This dissertation presents a comprehensive research study on the implementation of smart glasses (connected glasses) in the transition from manual assembly into complex hybrid assembly systems in Industry 5.0. The objective is to address the usability and impacts of these intelligent wearables in hybrid assembly lines and gather scientific knowledge and data on the practicality of utilizing smart wearables in such environments. The study underscores the significance of addressing the challenges posed by complex hybrid assembly lines and highlights the potential usage of smart glasses. The integration of smart glasses into a complex hybrid work environment, encompassing mechanical, pneumatic, and automated equipment, is explored from both an ergonomics and human factors perspective, as well as operational considerations. Smart glasses, despite their potential, have been little explored with regard to their joint micro/macro impacts. The study conducted an experimental evaluation (micro workstation level study) using Nielsen's framework to evaluate the usability and usefulness of smart glasses. Realistic scenarios were designed for a set of physical assembly scenarios on a simulated plane engine/turbine. Furthermore, instructions of assembly scenarios were planned both on paper and in smart glasses for comparison reasons which offered interesting results regarding quality and time aspects of the work. Extensively, STAMP-STPA and FRAM (systemic macro analysis) analysis were used to identify potential safety hazards and failures within a complex system of such as well as identifying interactions and dependencies among system elements and potential consequences of system changes. Experimental results indicate that there is no improvement in quality after the introduction of smart glasses (connected glasses). Although missed instructions were the same with and without smart glasses, more bolts were left loose after using the smart glasses and there were slightly fewer alignment errors with the smart glasses. The only significant reduction in completion time in the study was seen in scenario without smart glasses with pneumatic tool. Systemic analysis results indicate that the implementation of smart glasses in assembly processes resulted in variable worker performance influenced by experience and environmental factors, highlighting the need for comprehensive training and mechanisms feedback. Safety concerns include the risk of incorrect assembly or defective products due to eyewear errors. The study highlights the importance of improved clarity of instructions and two-way communication for enhanced safety These findings provide valuable insights into the practical considerations of implementing smart devices in such environments and offer recommendations for improving worker efficiency and effectiveness. Undoubtedly, smart glasses, despite their potential, have been little explored regarding their joint micro/macro impacts on operational indicators and ergonomic/human factors of such assembly systems. The results could serve as a basis for future developments and optimizations in the use of smart devices, hopefully improving efficiency in complex and hybrid assembly line operations. In conclusion, this research contributes to the understanding of the challenges and opportunities associated with the integration of smart glasses into complex and hybrid manufacturing systems, highlighting their potential to improve worker effectiveness and efficiency.

Date	19 Dec 2023
Original language	American English
Awarding Institution	École de technologie supérieure
Supervisor	Sylvie Nadeau (Supervisor)