A CAD-Based Tool to Support the Configuration of Parts Storage Shelving in Assembly Workstations

The supply of parts to the workstations of assembly lines is a critical design and operational issue. Even though automation and collaborative robots are increasingly used in industry, human operators are frequently employed in the picking and assembly of manual parts. These are time-consuming activities required to be efficiently performed at a high rate and for prolonged periods. Therefore, ergonomic analysis is necessary to reduce the risk of work-related musculoskeletal injuries due to the biomechanical loads. The proper layout of shelves storing part containers along the production line, and the location of the containers on the shelves, may improve picking efficiency and reduce biomechanical risk. Several manufacturing companies use computer-aided ergonomic tools to improve the design of manual production lines, racking, shelving, and workstations. This paper describes the development of a support tool to configure industrial light shelves for feeding the assembly lines. The approach includes the development of a knowledge base to support the geometrical configuration of the shelving and an ergonomic analysis based on the RULA method, considering the shelf’s position and the operator’s postures. As a test case, the model has been used to evaluate the ergonomic score of some configured shelving based on a prescribed picking sequence. The results show that the proposed approach can help in comparing the ergonomic score of candidate shelving layouts to improve the design of parts storage systems to reduce operators’ workload and ergonomic risk.