Salla Lind

Simulation-based sustainable manufacturing system design

Manufacturing simulation and digital engineering tools and procedures have had a positive impact on the manufacturing industry. However, to design a sustainable manufacturing system, a multitude of system dimensions must be jointly optimized. This paper proposes an integrated simulation tool helping to maximize production efficiency and balance environmental constraints already in the system design phase. Lean manufacturing, identification and elimination of waste and production losses, and environmental considerations are all needed during development of a sustainable manufacturing system. Engineers designing the manufacturing system need decision support, otherwise sub-optimization is more likely to occur. We present methods for calculating energy efficiency, CO2 emissions and other environmental impacts integrated into factory simulation software.

Occupational risks in industrial maintenance

Purpose – The aim of this paper is to describe the most important occupational risks in maintenance operations.Design/methodology/approach – This study analyzed all maintenance‐related fatalities since 1985 together with one group of severe accidents in Finland. In connection with the study, risk assessments were carried out in companies with the aim of charting the risks on sites.Findings – The results indicate that the typical risks in maintenance operations involve poor ergonomics and that the most severe risks among these can lead to direct injury. Severe or even fatal injuries are mainly caused by crushing or falling.Practical implications – To manage the risks, maintenance operations should be taken more carefully into account when designing and reconstructing machinery and work environments. It should be ensured that workers have relevant safety knowledge by means of risk assessments and instruction in safe working practice. In addition, safety cooperation with the customer is essential.Originality...

Safety risk assessment in industrial maintenance

Purpose – This paper aims to answer the following questions: What conditions must be taken into account in order to manage maintenance‐related risks? and how can the service‐providing company assess and manage maintenance‐related risks?Design/methodology/approach – The study was based on analyses concerning: maintenance‐related risks in companies; literature review; and real accident data. The development process was carried out in cooperation with companies providing maintenance services.Findings – Based on the findings, the method takes into account various risks relating to maintenance operations. The method includes specific parts for safety planning and hazard identification for managing maintenance safety. In addition, it provides a safety check‐list for the worker.Research limitations/implications – The usability and feasibility of the method should be reassessed and developed. The method could be especially useful in an electronic form.Practical implications – The method can be utilized for assess...

Safety of Interactive Robotics—Learning from Accidents

Finland is ranked rather high in international robot density statistics. In Finland, robots are typically used in applications where they operate in close proximity to humans. The research described in this paper, sourced from Finnish databases, identified 25 severe accidents which can be attributed to robots. The current accident data can provide an insight into the type of accidents associated with future human-robot interaction (HRI) applications. Accident statistics indicate that most of the severe robot-related accidents involved crushing a person against a rigid object. As crushing hazards currently dominate accident statistics, and with HRI applications becoming increasingly common, humans are expected to be exposed to more crushing hazards in the future. The close proximity of the robots means that there is very little time to escape from crushing hazard. The prevention of collisions between robots and humans is paramount to reducing the amount of accidents. Actions to diminish the effects of any subsequent collision are also important. The control after a collision, however, needs to be very quick in order to minimise the damage caused by an impact. Current practice demands that upon detection of a collision, active movements are typically not allowed without a human supervision. Moving a robot away to a safe position and releasing any pressure against a person may save lives, but would entail some adjustments or new interpretations of the current safety requirements.

Linking ergonomics simulation to production process development

Production development can conflict with production ergonomics and management of environmental impacts. In this paper, we describe how ergonomics can be assessed in production system design by means of a joint simulation tool. The tool enables ergonomics and environmental impacts assessment in conjunction with production process development. The ergonomics sub-tool is based on a digital human model, which has been improved by introducing an updated data measurement system and neural network processing and inference functionality. The results will extend the new simulation modelling capabilities of the existing digital human model by increasing the motion prediction accuracy and providing freedom to model a multitude of task-related motions in a realistic way.

A High-Level Haptic Interface for Enhanced Interaction within VirtoolsTM

Haptics is the outstanding technology to provide tri-dimensional interaction within Virtual Environments (VE). Nevertheless, many software solutions are not fully prepared to support Haptics. This paper presents a user-friendly implementation of Sensable Phantom haptic interfaces onto the interactive VE authoring platform, Virtools 4.0. Haptics implementation was realized using the Haptic Library (HLAPI) from OpenHaptics toolkit 2.0 which provides highly satisfactory custom forces effects. The integration of Phantom interaction at end-user development fulfils logical VE interactive authoring under Virtools. Haptics implementation was qualitatively assessed in a manual maintenance case, a welding task, as a part of the national Finnish project, VIRVO. Manipulation enhancements provided by the integration of Phantom interaction in Virtools suggest many further improvements for more complicated industrial pilot experiments as a part of the European Commission funded project ManuVAR.