An integrated ergonomic risk assessment framework based on fuzzy logic and IVSF-AHP for optimising ergonomic risks in a mixed-model assembly line

This study proposes a systematic approach to address ergonomic factors, including physical, environmental and psychosocial aspects, in solving assembly line balancing problems. A three-stage framework is developed, starting with determining weights for ergonomic risk assessment methods using the interval-valued spherical fuzzy analytical hierarchy process. In the second stage, a fuzzy logic model for integrated ergonomic risk assessment is constructed based on these weights, and the integrated ergonomic risk score is determined. In the third stage, a mathematical model is formulated to minimise the cycle time while balancing the ergonomic risk level. A case study conducted in a wire harness factory validated the effectiveness of the proposed approach, showing a 10–11% improvement in line efficiency and a 12–25% enhancement in ergonomic risk balancing performance. These findings underscore the potential benefits of implementing this approach, which can significantly improve occupational safety and overall performance. This article presents a practical and systematic approach for enhancing ergonomic conditions in assembly lines. The proposed approach aims to balance the ergonomic risk level while minimising the cycle time by considering physical, environmental and psychosocial risk factors. A case study conducted in a wire harness factory demonstrated significant improvements in balancing ergonomic risks, highlighting the real-world applicability of this research.本研究提出一种系统性方法，用于在解决装配线平衡问题时考量人体工效学因素，涵盖物理、环境与社会心理三大维度。该研究构建了三阶段分析框架：首先借助区间值球面模糊层次分析法（interval-valued spherical fuzzy analytical hierarchy process）确定人体工效学风险评估方法的权重；第二阶段基于上述权重搭建集成人体工效学风险评估的模糊逻辑模型，并计算得到集成人体工效学风险评分；第三阶段构建数学优化模型，在平衡人体工效学风险水平的同时最小化生产节拍时间。本研究在线束工厂开展的案例研究验证了所提方法的有效性：生产线效率提升10%~11%，人体工效学风险平衡性能改善12%~25%。上述研究结果凸显了该方法的应用价值，其可显著提升职业安全水平与整体生产绩效。本文提出了一种可用于改善装配线人体工效学状况的实用系统性方法，所提方法通过考量物理、环境与社会心理风险因素，在最小化生产节拍的同时实现人体工效学风险水平的均衡。线束工厂的案例研究证实，该方法可显著优化人体工效学风险平衡效果，凸显了本研究的实际应用价值。