Analysis of working postures in a wiring harness conveyor line with AnyBody Modeling System and design proposal of a new line

Abstract

Ergonomically unsuitable working postures are encountered in labor-intensive companies. These postures in production have a negative affect on the performance, quality, costs, and productivity. In this study, a wiring harness conveyor line was investigated in a company that performs complete wiring harness for automobiles. To evaluate the stress on the muscles caused by unsuitable postures, the AnyBody Modeling System was used. The analysis demonstrated excessively high joint reaction forces in the trunk, shoulders, arms, and legs, which can cause musculoskeletal disorders. Therefore, a new conveyor line design that can reduce the workload on operators is proposed. The working postures in the proposed design were analyzed, and the new design significantly improved the working postures. Then, the prototype conveyor line design was produced. Working postures on the produced prototype were also analyzed. The validated conveyor was manufactured, and final analyses showed that the workload on the trunk, shoulders, arms, and legs was decreased. This produced prototype is a useful example for other similar conveyor lines.