This thesis presents a product development project done at Scania Ferruform in Luleå. The process that was used is called Stage-Gating which means that the project is divided into gates. The gates used in this project were the following: Planning, Concept development, Ergonomic analysis, Analysis of culture and work environment, Refinement & Documentation. The purpose was to generate concepts that lowers the overall load on the operators at the crossmember painting lines unloading station, to better the production. The subsystems investigated in this project were the following: Trolley, Hooks, Lifting table (+Control panel) & Pallets (Packaging). The mission from Scania was to analyse, concept generate, find tools and solutions to the crossmember painting line. The aim was to deliver: Foundation of product development regarding the unloading station, Ergonomic evaluations of the chosen concept towards today’s station, Analysis of work environment and culture & Report. The project was started by interviewing operators and leaders to get a clear picture of the current situation and what has been done so far. The method to reach the desired solutions consists mainly of concept generation. To evaluate and choose concept, Screening and Scoring was used which ensures that the best possible concept is chosen. The chosen concept that is called Concept 3 includes 14 new functions where some functions are more important than others. The results show that Concept 3 will perform 30–60 % better regarding ergonomics than today’s station. It also shows that at the average of the amount of lifts per takt, the ergonomic evaluation get a red evaluation in the zones where the operators work the most. Culture and work environment shows that skepticism towards the management is deeply rooted in the culture which leads to a worker collective to form. In turn, this leads to that unhealthy working conditions is enforced by the culture itself. More results can be seen in the section Results & Discussion. One of the most important conclusions is that even if the chosen concept improves the ergonomics, it does not eliminate the extreme loads and the extent of beams the operators are lifting daily. Even with proof of improvement, it is impossible to eliminate the immense load — which leads to that something else than the operator have to take up the force of the beams. Manual handling is therefore not an option to consider.

This master thesis was performed in collaboration with Scania Ferruform in Luleå, with the purpose to create an efficient, rational and safe workplace at the unloading station of the crossmember painting line. The mission from Ferruform was to investigate and analyse flaws, risk, and bottlenecks with regards to flows, ergonomics and material handling. The project aimed to create a vision that could guide present and future development, followed by an implementation strategy consisting of concrete measures of both layout and organisational character. The vision is: “Create a work situation that is rooted in Scania's production system and characterized by efficiency, rationality and safe working conditions, where committed individuals can be challenged and developed”   The research questions that has guided the project are: What problem is the basis for the ergonomic situation at the crossmember painting? How can an efficient and rational workplace be created at crossmember painting? What does Ferruform need to do to create a safe and sustainable work environment at the crossmember painting?   The first step was to map the current state and identify problems with regards to process and organisation. This was done by using participative observation, interviews, user participation, overview analysis and Scania’s intranet. Apart from previous studies, the main problems that the mapping identified was consequences of frequent downtimes, shifts being isolated and having unique work methods, unsafe work environment, and finally that tools and aids for reducing harmful lifts are not used.  These problems and their consequences were analysed with regards to the current research in work science, behavioural science, and by using methods such as Fault tree analysis and proximity chart. One of the most important conclusions was that downtime, apart from compromised production volumes, affected the work situation negatively. Operators compensate for downtime by working faster and unsafe to reach the weekly production goals. Additionally, a middle manager role has disappeared in favour of meeting the production goals. This has severe consequences on the organisation of work and among others, ergonomics. The proximity chart showed that placement of functions in the production system is not based on logic, resulting in safety issues, intersecting flows and inefficient handling of materials. To counter the identified problems, three different layouts were developed and evaluated using the specification of requirements. The concept with highest score was further developed and detail designed. It is called “Wing” and separates humans and forklifts, has a centralized material buffer and redundancy for downtime. The concept allows for safer work environment, and efficient flows. The required changes are arranged in three steps, each with increasing capacity. The final concept together with the implementation plan, which present recommendations on how the final concept could gradually be implemented and what organisational changes that are needed, shows that productivity and rationality can coexist with a good work environment, where both humans and the production system can flourish.

Aktionskräfte stellen wesentliche Risikofaktoren für die Entstehung von Erkrankungen im Finger-, Hand- und Armbereich dar. Daher ist die Erfassung und Analyse von Aktionskräften ein wichtiger Bestandteil der ergonomischen Bewertung von Arbeitsplätzen. Zur Erfassung von Aktionskräften, insbesondere in der Automobilproduktion, existiert bisher jedoch weder eine einheitliche noch eine systematische Vorgehensweise. Es mangelt an konkreten Forschungserkenntnissen über den Messaufbau, die Messdurchführung und die Messauswertung von Kraftfällen. In der vorliegenden Arbeit wird deshalb ein erster Schritt unternommen, um die Erfassung von Aktionskräften auf Basis wissenschaftlich gestützter Erkenntnisse zu standardisieren. Hierzu werden insgesamt vier empirische Untersuchungen (zwei Vorstudien und zwei empirische Laborstudien) durchgeführt. In der ersten Studie (Kapitel 4) erfolgt eine Identifizierung der vorhandenen Arten von Kraftaufwendungen in verschiedenen Fertigungsbereichen der Automobilproduktion im Rahmen einer Dokumentenanalyse. In der zweiten Studie (Kapitel 5) wird der bedeutendste Fertigungsbereich ausgewählt, um darin eine Auszählung der Kraftaufwendungen anhand einer standardisierten Beobachtung definierter Arbeitsprozesse durchzuführen. Die dritte Untersuchung (Kapitel 6) ist als empirische Laborstudie konzipiert. Darin wird die technische Erfassung von Aktionskräften unter idealisierten Bedingungen ohne menschlichen Einfluss erprobt. In der vierten Untersuchung (Kapitel 7), ebenfalls als empirische Laborstudie konzipiert, werden spezifische Kraftaufwendungen im Labor systematisch durch Probanden nachgestellt und gemessen. Dabei wird das Vorgehen zur Durchführung und Auswertung von praxisnahen Kraftmessungen unter menschlichem Einfluss evaluiert. Die Erkenntnisse der Arbeit helfen dabei, bestehende Forschungsdefizite aufzuarbeiten und zu beheben. Sie stellen ferner eine Handlungshilfe für betriebliche Kraftanalysen sowie eine Orientierung für zukünftige Forschungsarbeiten dar. / Action forces have been identified as risk factors. Therefore, the collection and analysis of action forces is an essential part of the ergonomic evaluation. Up to now, there was a lack of a standardized and systematic approach to evaluate action forces, especially in the automotive production. Thus, in the present thesis a methodical approach is described to evaluate action forces systematically. The thesis is divided into four studies. The first study contains the identification of the variety of action forces in the different manufacturing areas of automotive production. The second study describes the detailed analysis of action forces in the assembly shop, which is the manufacturing area with the highest count of action forces in the automotive production. The third study describes the direct measurement of action forces in laboratory conditions. The action forces are applied by a testing machine. The fourth study consists of the direct measurement of action forces, which are applied by subjects. Thereby, the methodical approach to perform direct measurements has been evaluated. The findings of the thesis can be used as a guideline, to evaluate action forces in the automotive production. Also the findings highlight the potential for further research projects.