This work extends the assembly line balancing problem by considering the limitation of workload related to harmful tasks, in ergonomic terms, within workstations. The problem is further developed by incorporating a new objective: balancing the harmful workload across stations to ensure a homogeneous distribution of harmful tasks and prevent disproportionate worker exposure. Three mathematical models are proposed to minimize (1) the maximum time dedicated to harmful tasks, (2) the deviation between the time allocated to harmful tasks and the maximum allowable time, and (3) the average absolute deviation of the time assigned to harmful tasks. Computational results indicate that the model minimizing the average absolute deviation of time spent on harmful tasks is the most competitive, achieving optimal solutions with low execution times. However, the model that provides the best results in terms of ergonomic equity –by significantly improving the deviation in harmful workload while maintaining line efficiency– is the one that minimizes the maximum time. The results highlight the importance of an integrated approach that combines production efficiency and ergonomic equity in assembly line balancing, paving the way for risk compensation between stations with and without harmful tasks through job rotation.

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Balancing Assembly Lines by Regulating Exposure to Ergonomically Hazardous Tasks

  • Rocío Alfaro-Pozo,
  • Joaquín Bautista-Valhondo

摘要

This work extends the assembly line balancing problem by considering the limitation of workload related to harmful tasks, in ergonomic terms, within workstations. The problem is further developed by incorporating a new objective: balancing the harmful workload across stations to ensure a homogeneous distribution of harmful tasks and prevent disproportionate worker exposure. Three mathematical models are proposed to minimize (1) the maximum time dedicated to harmful tasks, (2) the deviation between the time allocated to harmful tasks and the maximum allowable time, and (3) the average absolute deviation of the time assigned to harmful tasks. Computational results indicate that the model minimizing the average absolute deviation of time spent on harmful tasks is the most competitive, achieving optimal solutions with low execution times. However, the model that provides the best results in terms of ergonomic equity –by significantly improving the deviation in harmful workload while maintaining line efficiency– is the one that minimizes the maximum time. The results highlight the importance of an integrated approach that combines production efficiency and ergonomic equity in assembly line balancing, paving the way for risk compensation between stations with and without harmful tasks through job rotation.