Maria Antónia Gonçalves - Academia.edu (original) (raw)
Papers by Maria Antónia Gonçalves
Studies in Systems, Decision and Control, 2019
Nowadays, the competitiveness between organizations is a growing reality. The Lean philosophy has... more Nowadays, the competitiveness between organizations is a growing reality. The Lean philosophy has proven to help companies improve their productivity and reduce waste. The relationship between lean and safety, Lean Safety, is not clearly understood, which should not be the case, since these two concepts are compatible and both strive to improve processes. This paper presents a new methodology designated Safety Steam Mapping (SSM). The SSM is a methodology based on VSM (Value Stream Mapping) and WID (Waste Identification Diagram) that allows, through the observation of a color scheme, to perceive the areas/processes belonging to the productive flow of the organization, what is the associated risk and what is the cause of the lack of safety, thus facilitating the understanding of the company’s risk assessment. The SSM was designed in order to assist any member of an organization, internal or external, to perceive the safety state of the organization. The main goal of this methodology is to provide all stakeholders a macro view and easy interpretation of the level of safety and risk level of the areas/processes of the company. A case study of a textile enterprise is presented, as well as, the respective results.
Occupational and Environmental Safety and Health II, 2020
The purpose of this work was to implement selected Lean tools—5S, Visual Management and One Point... more The purpose of this work was to implement selected Lean tools—5S, Visual Management and One Point Lesson (OPL) considering the problems identified in the contract under the study, to promote the change of workers’ behaviours, improve the work environment and consequently Safety and Health Conditions at Work (SHCW). Another objective was to analyse the impact of Lean tools on SHCW, taking into account the real perception of workers. To this end, a questionnaire on safety culture was made available to workers before and after the implementation of some Lean tools, as referred above. It was found that Lean Thinking and its tools are an added value for improving work conditions. Benefits such as the best warehouse organization and physic location (e.g., reduction in about 80% of the route and time in travel to search for materials and tools are highlighted); better organization of infrastructure workshops I and II (e.g., elimination of unnecessary items, tools’ organization, layout changes); 41 and 38% increase in the results of 5S audits to infrastructure workshops I and II, respectively; improvement of working practices with the creation of OPL’s for the wagons transport and purge of the oxiperm system pump. Concerning employees’ perception of the Lean tools implementation and their impact on the work conditions, it was found that 83.4% of workers agree that the work environment has been improved.
Occupational and Environmental Safety and Health II, 2020
In the original version of the book, the following belated correction has been incorporated: The ... more In the original version of the book, the following belated correction has been incorporated: The author name "Patrício Cordeiro" has been amended correctly as "P. Cordeiro". The chapter and book have been updated with the changes.
The absenteeism related to health and safety at work is a serious issue in the manufacturing proc... more The absenteeism related to health and safety at work is a serious issue in the manufacturing process, and some industries can be dangerous work fields with a high level of accidents. It is important to understand what causes the accident and, if possible, apply standard procedures to minimize the risk of accidents and subsequent absenteeism. This study aims to assess the impact of the implementation of occupational health and safety procedures on company absenteeism. In the company where the study took place, most work accidents and absenteeism happened in the production area, with workers who directly handle raw materials and machines. As a result, an HSE manager was hired in order to reduce accidents by putting in place several hygiene and security measures and procedures. The results of these measures as well as absenteeism data were studied and conclusions regarding company performance were drawn.
Nowadays there is an increasing concern for well- being. However, workers continue to suffer from... more Nowadays there is an increasing concern for well- being. However, workers continue to suffer from musculoskeletal disorders, which are one of the most widely recognized types of occupational disease. Meat cutters face higher risks of injury and musculoskeletal problems than most other occupational groups due to repetition, force, static posture, work organization, and lack of recovery time. The aim of this paper is to use a continuous improvement audit tool to analyze the current situation of a piglet cutting workstation and then identify measures to improve it, considering productivity and workers’ well-being.info:eu-repo/semantics/publishedVersio
Advances in Human Factors and Ergonomics Series, 2010
This study has been carried out to evaluate the number of mismatches between secondary girl stude... more This study has been carried out to evaluate the number of mismatches between secondary girl student's anthropometry and existing furniture dimensions in Bangladesh. In this study, 375 students (girls) are in classes 6-10 in the age group between 10-15 years that have randomly selected from three secondary girl schools in Bangladesh. Twelve anthropometric measurements and seven existing furniture dimensions were taken to find out the possible mismatch. A defined match criterion equation used to determine the mismatch. Various researchers gave these equations. The result indicates that there is a significant mismatch between anthropometric measurement and furniture dimensions. The highest mismatch percentage for seat height is about 90% for class 9. Therefore, 90% of girls use the seat that is too high (high mismatch). Mismatch percentage for seat depth is 100% for all classes. As a result, seat depth is so small for all students. Seat width is 100% for class 8 and 60% for class 9. The desktop height is about 100% mismatch for all classes. This paper also proposes dimensions for new furniture. The new furniture improves the match percentages from 50% to 100%.
Efetivamente, o objetivo da ergonomia e o estudo integrado da envolvente do trabalho, cujo objeti... more Efetivamente, o objetivo da ergonomia e o estudo integrado da envolvente do trabalho, cujo objetivo e aumentar a eficiencia, a seguranca e, consequentemente, a produtividade dos trabalhadores. O posto de trabalho enquanto o espaco que o trabalhador ocupa quando desempenha uma tarefa, a organizacao do trabalho, com modos operatorios e meios adequados de trabalho, com planeamento eficiente, formacao adequada, tempo e pausas de trabalho estipuladas e em que os trabalhadores tenham responsabilidades definidas e autonomia de decisao, o conteudo do trabalho, o ambiente de trabalho que engloba as condicoes em que as tarefas sao executadas sao essenciais para o bom desempenho das tarefas. Para alem do impacto evidente sobre a seguranca e saude dos trabalhadores, a ergonomia tem um papel fundamental na produtividade, eficiencia e, consequentemente, na motivacao. Em sintese, este artigo visa mostrar que a ergonomia nao se debruca apenas nas dimensoes corporais para a concecao dos postos de tr...
Studies in Systems, Decision and Control, 2021
Procedia Manufacturing, 2020
Abstract This paper intends to apply and improve a workstation assessment tool called ErgoSafeCI.... more Abstract This paper intends to apply and improve a workstation assessment tool called ErgoSafeCI. Lean manufacturing methods and guidelines, together with safety and ergonomics aspects, were thoroughly researched with the ultimate objective of finding a way to improve the workplace by considering the efficiency and well-being of workers. The assessment tool was applied in the plastics packaging sector, in a process which relied on both practical and theoretical ideas. This tool originates in the notion that for a successful Lean implementation, managers should start the Lean process with a Lean assessment which is then repeated on a regular basis. In addition, it is also important to integrate ergonomic conditions in this journey because ergonomic risks can sometimes result in Lean wastes and vice versa, so workplace ergonomics and Lean manufacturing are to a great extent inter-related. This tool aids practitioners in the assessment of the implementation of Lean principles and safety matters in their processes.
The Open Cybernetics & Systemics Journal, 2018
Background: The study described in this work took place in the sanding and polishing area of a me... more Background: The study described in this work took place in the sanding and polishing area of a meta-lurgical company, where workers' complaints due to the strength needed to perform manual tasks, as well as their repetitive pattern, led to cases of shoulder pain and tendinitis.
Procedia Manufacturing, 2019
International Journal of Lean Six Sigma, 2019
Purpose The purpose of this paper is to present an attempt to develop an instrument containing op... more Purpose The purpose of this paper is to present an attempt to develop an instrument containing operational measures of lean combined with safety and ergonomic conditions in a workstation or production line. This operational tool aims to help researchers and practitioners to prioritize and evaluate the lean implementations, as well as the ergonomic and safety conditions, in an integrated way. Design/methodology/approach Lean manufacturing methods and principles, as well as safety and ergonomics aspects, were exhaustively researched with the ultimate goal of finding a way to improve the workplace by taking into account the efficiency and well-being of workers. The instrument was validated in an interactive process between theory and practical insights. At the end, it was tested in several workstations/production areas. Findings The study reveals that high scores are derived from a good interaction between lean, ergonomics and safety. Research limitations/implications It would be impor...
Lean Engineering for Global Development, 2019
In 2015, the UN defined well-being and decent work/economic growth as two of 17 sustainable devel... more In 2015, the UN defined well-being and decent work/economic growth as two of 17 sustainable development objectives. Nevertheless, the extreme pressure for businesses to be competitive in their markets of choice seems to be having a negative effect on workers’ well-being. In the manufacturing sector, the effective inclusion of Ergonomics in processes and installations has been proven to decrease costs related to disability, extra or overtime hours, medical care and premiums or fines for occurrences. The aim of this work was to review the existing scientific knowledge about the impact of adopting LPS (Lean Production Systems—a model used to increase competitiveness by the creation of more value for customers with fewer resources) in manufacturing companies from the point of view of Ergonomics. It reports, based on the literature reviewed, how the integration of both LPS and Ergonomics principles, from the workstation design phase onwards, can bring benefits to the workers’ welfare and simultaneously potentiate improvements in productivity. This paper also intends to present trends and opportunities for future research in this area, including in the Industry 4.0 field. In the authors’ opinion, this paper is a valuable contribution for practitioners, in manufacturing environments, and researchers.
International Journal of Occupational and Environmental Safety, 2018
Striving to improve productivity, industries have used different management approaches, being lea... more Striving to improve productivity, industries have used different management approaches, being lean manufacturing the most used over recent years. Lean manufacturing is based on value creation for the customer and elimination of waste that occurs during the production process, while improving working conditions. The incorporation of ergonomic aspects in the workstation design also contributes for the referred objectives, since it will reduce awkward postures or excessive effort during work, leading to better working conditions and increased productivity. The present study highlights, through a case study in four production areas of a metallurgical industry, the benefits of using an integrated operations management approach to improve productivity and ergonomic aspects. Several ergonomic methods, such as Rapid Upper Limb Assessment (RULA), Strain Index (SI), and Rapid Entire Body Assessment (REBA), were chosen to evaluate the ergonomic situation and lean manufacturing tools such as Va...
Procedia Manufacturing, 2017
The aim of this study is to prove that it is possible to reduce the setup time and improve ergono... more The aim of this study is to prove that it is possible to reduce the setup time and improve ergonomic conditions at the same time. This research took place in a turning production area of a metallurgical factory where workers' complains due to shoulder pains and tendinitis were high, due to the awkward postures and forceful hand exertions to perform the manual tasks. Moreover, the high setup time of 105 minutes caused productivity problems and delays for customers. Through the SMED tool and increasing ergonomic conditions, the setup time was reduced 46% and the MSD risk also decreased. This study demonstrated that ergonomic condition' improvements considered in a lean process help in the achievement of good results and it is very important to consider ergonomic conditions at the project phase, otherwise changes in the equipment could be very expensive, and difficult to justify.
Occupational Safety and Hygiene V, 2017
The aim of this study is to redesign two workstations in a PVD coating production area, consideri... more The aim of this study is to redesign two workstations in a PVD coating production area, considering productivity and ergonomic aspects. Through the elimination of wastes such as unnecessary movements and transportations and by reducing the awkward postures as arm flexion larger than 45º, the productivity in the loading and unloading workstations increased 9% and 5%, respectively, and the ergonomic risk was improved from medium to acceptable. RULA was the chosen method to evaluate the ergonomic situation and anthropometric studies were performed to find the ideal ergonomic solution. This study shows the importance to consider ergonomic conditions when designing or redesigning a workstation in order to get effective productivity improvements.
Abstract. During the last decades of the previous century, school desks with a tilt top have disa... more Abstract. During the last decades of the previous century, school desks with a tilt top have disappeared. The chairs have been designed for sitting upright, with the hip, knees and ankles all at right angles. However, the erect posture cannot be maintained for more than one or two minutes, after which it will result in fatigue, discomfort or poor posture. The main aim of project is to identify the type of furniture that most effectively contribute to adequate neck and back postures of the school children, by carrying out a postural analysis of a sample of school pupils when using three different types of furniture. The postures adopted by school pupils were monitored by video during several activities, such as reading, writing and painting tasks, copying from a blackboard and listening the teacher. Additionally, the characteristics of the adopted postures were assessed by registering the head tilt, flexion of the neck, trunk and hips position. All these aspects were classified and t...
Studies in Systems, Decision and Control, 2019
Nowadays, the competitiveness between organizations is a growing reality. The Lean philosophy has... more Nowadays, the competitiveness between organizations is a growing reality. The Lean philosophy has proven to help companies improve their productivity and reduce waste. The relationship between lean and safety, Lean Safety, is not clearly understood, which should not be the case, since these two concepts are compatible and both strive to improve processes. This paper presents a new methodology designated Safety Steam Mapping (SSM). The SSM is a methodology based on VSM (Value Stream Mapping) and WID (Waste Identification Diagram) that allows, through the observation of a color scheme, to perceive the areas/processes belonging to the productive flow of the organization, what is the associated risk and what is the cause of the lack of safety, thus facilitating the understanding of the company’s risk assessment. The SSM was designed in order to assist any member of an organization, internal or external, to perceive the safety state of the organization. The main goal of this methodology is to provide all stakeholders a macro view and easy interpretation of the level of safety and risk level of the areas/processes of the company. A case study of a textile enterprise is presented, as well as, the respective results.
Occupational and Environmental Safety and Health II, 2020
The purpose of this work was to implement selected Lean tools—5S, Visual Management and One Point... more The purpose of this work was to implement selected Lean tools—5S, Visual Management and One Point Lesson (OPL) considering the problems identified in the contract under the study, to promote the change of workers’ behaviours, improve the work environment and consequently Safety and Health Conditions at Work (SHCW). Another objective was to analyse the impact of Lean tools on SHCW, taking into account the real perception of workers. To this end, a questionnaire on safety culture was made available to workers before and after the implementation of some Lean tools, as referred above. It was found that Lean Thinking and its tools are an added value for improving work conditions. Benefits such as the best warehouse organization and physic location (e.g., reduction in about 80% of the route and time in travel to search for materials and tools are highlighted); better organization of infrastructure workshops I and II (e.g., elimination of unnecessary items, tools’ organization, layout changes); 41 and 38% increase in the results of 5S audits to infrastructure workshops I and II, respectively; improvement of working practices with the creation of OPL’s for the wagons transport and purge of the oxiperm system pump. Concerning employees’ perception of the Lean tools implementation and their impact on the work conditions, it was found that 83.4% of workers agree that the work environment has been improved.
Occupational and Environmental Safety and Health II, 2020
In the original version of the book, the following belated correction has been incorporated: The ... more In the original version of the book, the following belated correction has been incorporated: The author name "Patrício Cordeiro" has been amended correctly as "P. Cordeiro". The chapter and book have been updated with the changes.
The absenteeism related to health and safety at work is a serious issue in the manufacturing proc... more The absenteeism related to health and safety at work is a serious issue in the manufacturing process, and some industries can be dangerous work fields with a high level of accidents. It is important to understand what causes the accident and, if possible, apply standard procedures to minimize the risk of accidents and subsequent absenteeism. This study aims to assess the impact of the implementation of occupational health and safety procedures on company absenteeism. In the company where the study took place, most work accidents and absenteeism happened in the production area, with workers who directly handle raw materials and machines. As a result, an HSE manager was hired in order to reduce accidents by putting in place several hygiene and security measures and procedures. The results of these measures as well as absenteeism data were studied and conclusions regarding company performance were drawn.
Nowadays there is an increasing concern for well- being. However, workers continue to suffer from... more Nowadays there is an increasing concern for well- being. However, workers continue to suffer from musculoskeletal disorders, which are one of the most widely recognized types of occupational disease. Meat cutters face higher risks of injury and musculoskeletal problems than most other occupational groups due to repetition, force, static posture, work organization, and lack of recovery time. The aim of this paper is to use a continuous improvement audit tool to analyze the current situation of a piglet cutting workstation and then identify measures to improve it, considering productivity and workers’ well-being.info:eu-repo/semantics/publishedVersio
Advances in Human Factors and Ergonomics Series, 2010
This study has been carried out to evaluate the number of mismatches between secondary girl stude... more This study has been carried out to evaluate the number of mismatches between secondary girl student's anthropometry and existing furniture dimensions in Bangladesh. In this study, 375 students (girls) are in classes 6-10 in the age group between 10-15 years that have randomly selected from three secondary girl schools in Bangladesh. Twelve anthropometric measurements and seven existing furniture dimensions were taken to find out the possible mismatch. A defined match criterion equation used to determine the mismatch. Various researchers gave these equations. The result indicates that there is a significant mismatch between anthropometric measurement and furniture dimensions. The highest mismatch percentage for seat height is about 90% for class 9. Therefore, 90% of girls use the seat that is too high (high mismatch). Mismatch percentage for seat depth is 100% for all classes. As a result, seat depth is so small for all students. Seat width is 100% for class 8 and 60% for class 9. The desktop height is about 100% mismatch for all classes. This paper also proposes dimensions for new furniture. The new furniture improves the match percentages from 50% to 100%.
Efetivamente, o objetivo da ergonomia e o estudo integrado da envolvente do trabalho, cujo objeti... more Efetivamente, o objetivo da ergonomia e o estudo integrado da envolvente do trabalho, cujo objetivo e aumentar a eficiencia, a seguranca e, consequentemente, a produtividade dos trabalhadores. O posto de trabalho enquanto o espaco que o trabalhador ocupa quando desempenha uma tarefa, a organizacao do trabalho, com modos operatorios e meios adequados de trabalho, com planeamento eficiente, formacao adequada, tempo e pausas de trabalho estipuladas e em que os trabalhadores tenham responsabilidades definidas e autonomia de decisao, o conteudo do trabalho, o ambiente de trabalho que engloba as condicoes em que as tarefas sao executadas sao essenciais para o bom desempenho das tarefas. Para alem do impacto evidente sobre a seguranca e saude dos trabalhadores, a ergonomia tem um papel fundamental na produtividade, eficiencia e, consequentemente, na motivacao. Em sintese, este artigo visa mostrar que a ergonomia nao se debruca apenas nas dimensoes corporais para a concecao dos postos de tr...
Studies in Systems, Decision and Control, 2021
Procedia Manufacturing, 2020
Abstract This paper intends to apply and improve a workstation assessment tool called ErgoSafeCI.... more Abstract This paper intends to apply and improve a workstation assessment tool called ErgoSafeCI. Lean manufacturing methods and guidelines, together with safety and ergonomics aspects, were thoroughly researched with the ultimate objective of finding a way to improve the workplace by considering the efficiency and well-being of workers. The assessment tool was applied in the plastics packaging sector, in a process which relied on both practical and theoretical ideas. This tool originates in the notion that for a successful Lean implementation, managers should start the Lean process with a Lean assessment which is then repeated on a regular basis. In addition, it is also important to integrate ergonomic conditions in this journey because ergonomic risks can sometimes result in Lean wastes and vice versa, so workplace ergonomics and Lean manufacturing are to a great extent inter-related. This tool aids practitioners in the assessment of the implementation of Lean principles and safety matters in their processes.
The Open Cybernetics & Systemics Journal, 2018
Background: The study described in this work took place in the sanding and polishing area of a me... more Background: The study described in this work took place in the sanding and polishing area of a meta-lurgical company, where workers' complaints due to the strength needed to perform manual tasks, as well as their repetitive pattern, led to cases of shoulder pain and tendinitis.
Procedia Manufacturing, 2019
International Journal of Lean Six Sigma, 2019
Purpose The purpose of this paper is to present an attempt to develop an instrument containing op... more Purpose The purpose of this paper is to present an attempt to develop an instrument containing operational measures of lean combined with safety and ergonomic conditions in a workstation or production line. This operational tool aims to help researchers and practitioners to prioritize and evaluate the lean implementations, as well as the ergonomic and safety conditions, in an integrated way. Design/methodology/approach Lean manufacturing methods and principles, as well as safety and ergonomics aspects, were exhaustively researched with the ultimate goal of finding a way to improve the workplace by taking into account the efficiency and well-being of workers. The instrument was validated in an interactive process between theory and practical insights. At the end, it was tested in several workstations/production areas. Findings The study reveals that high scores are derived from a good interaction between lean, ergonomics and safety. Research limitations/implications It would be impor...
Lean Engineering for Global Development, 2019
In 2015, the UN defined well-being and decent work/economic growth as two of 17 sustainable devel... more In 2015, the UN defined well-being and decent work/economic growth as two of 17 sustainable development objectives. Nevertheless, the extreme pressure for businesses to be competitive in their markets of choice seems to be having a negative effect on workers’ well-being. In the manufacturing sector, the effective inclusion of Ergonomics in processes and installations has been proven to decrease costs related to disability, extra or overtime hours, medical care and premiums or fines for occurrences. The aim of this work was to review the existing scientific knowledge about the impact of adopting LPS (Lean Production Systems—a model used to increase competitiveness by the creation of more value for customers with fewer resources) in manufacturing companies from the point of view of Ergonomics. It reports, based on the literature reviewed, how the integration of both LPS and Ergonomics principles, from the workstation design phase onwards, can bring benefits to the workers’ welfare and simultaneously potentiate improvements in productivity. This paper also intends to present trends and opportunities for future research in this area, including in the Industry 4.0 field. In the authors’ opinion, this paper is a valuable contribution for practitioners, in manufacturing environments, and researchers.
International Journal of Occupational and Environmental Safety, 2018
Striving to improve productivity, industries have used different management approaches, being lea... more Striving to improve productivity, industries have used different management approaches, being lean manufacturing the most used over recent years. Lean manufacturing is based on value creation for the customer and elimination of waste that occurs during the production process, while improving working conditions. The incorporation of ergonomic aspects in the workstation design also contributes for the referred objectives, since it will reduce awkward postures or excessive effort during work, leading to better working conditions and increased productivity. The present study highlights, through a case study in four production areas of a metallurgical industry, the benefits of using an integrated operations management approach to improve productivity and ergonomic aspects. Several ergonomic methods, such as Rapid Upper Limb Assessment (RULA), Strain Index (SI), and Rapid Entire Body Assessment (REBA), were chosen to evaluate the ergonomic situation and lean manufacturing tools such as Va...
Procedia Manufacturing, 2017
The aim of this study is to prove that it is possible to reduce the setup time and improve ergono... more The aim of this study is to prove that it is possible to reduce the setup time and improve ergonomic conditions at the same time. This research took place in a turning production area of a metallurgical factory where workers' complains due to shoulder pains and tendinitis were high, due to the awkward postures and forceful hand exertions to perform the manual tasks. Moreover, the high setup time of 105 minutes caused productivity problems and delays for customers. Through the SMED tool and increasing ergonomic conditions, the setup time was reduced 46% and the MSD risk also decreased. This study demonstrated that ergonomic condition' improvements considered in a lean process help in the achievement of good results and it is very important to consider ergonomic conditions at the project phase, otherwise changes in the equipment could be very expensive, and difficult to justify.
Occupational Safety and Hygiene V, 2017
The aim of this study is to redesign two workstations in a PVD coating production area, consideri... more The aim of this study is to redesign two workstations in a PVD coating production area, considering productivity and ergonomic aspects. Through the elimination of wastes such as unnecessary movements and transportations and by reducing the awkward postures as arm flexion larger than 45º, the productivity in the loading and unloading workstations increased 9% and 5%, respectively, and the ergonomic risk was improved from medium to acceptable. RULA was the chosen method to evaluate the ergonomic situation and anthropometric studies were performed to find the ideal ergonomic solution. This study shows the importance to consider ergonomic conditions when designing or redesigning a workstation in order to get effective productivity improvements.
Abstract. During the last decades of the previous century, school desks with a tilt top have disa... more Abstract. During the last decades of the previous century, school desks with a tilt top have disappeared. The chairs have been designed for sitting upright, with the hip, knees and ankles all at right angles. However, the erect posture cannot be maintained for more than one or two minutes, after which it will result in fatigue, discomfort or poor posture. The main aim of project is to identify the type of furniture that most effectively contribute to adequate neck and back postures of the school children, by carrying out a postural analysis of a sample of school pupils when using three different types of furniture. The postures adopted by school pupils were monitored by video during several activities, such as reading, writing and painting tasks, copying from a blackboard and listening the teacher. Additionally, the characteristics of the adopted postures were assessed by registering the head tilt, flexion of the neck, trunk and hips position. All these aspects were classified and t...