Development of a Safety Monitoring Framework for Ergonomically Critical Stations in Assembly Lines

Abstract

In modern industrial manufacturing, particularly in heavy equipment assembly like hydraulic excavators, ergonomics and operator safety are critical to ensuring both productivity and worker well-being. This project focuses on the development of a comprehensive Safety Monitoring Framework specifically designed for ergonomically critical stations within hydraulic excavator assembly lines. These stations typically involve high physical strain, awkward postures, repetitive motions, and manual handling of heavy components all of which can lead to musculoskeletal disorders (MSDs), reduced efficiency, and increased safety risks. The proposed framework integrates ergonomic assessment tools with real-time monitoring systems to identify and mitigate potential safety hazards. Key components include the use of motion capture technology, wearable sensors, and computer vision to track body posture, movement patterns, and force exertions. This data is then analyzed using established ergonomic assessment methods such as RULA (Rapid Upper Limb Assessment) and REBA (Rapid Entire Body Assessment) to score risk levels. Based on this scoring, the system provides feedback and alerts to operators and supervisors, recommending corrective actions or workstation redesigns. The framework incorporates a data-driven feedback loop that continuously learns from historical data to predict high-risk scenarios and suggest preemptive measures. The integrating this framework with existing assembly line workflows, the project aims to reduce workplace injuries, enhance ergonomic compliance, and improve overall productivity.