Data collection and analysis of manual work using video recording and personal computer techniques

This paper initially reports on data collection and analysis of assembly systems including manual work using the so-called 'loss analysis' which we have applied within the automotive industry during two decades of research and development work. In the further development of this method of analysis we have during the last few years synchronized a personal computer and a video recorder, thereby facilitating data collection of true shop floor information, as well as developing the analysis procedure to also include ergonomic aspects and work performance in the analysis. This paper reports on: (1) the background, (2) the prototype equipment used for data collection and analysis which is illustrated by empirical data using the equipment to analyse stamping of sheet metal, as well as assembly of automobile doors and drivelines, and (3) how to integrate a 'loss analysis' with an ergonomic analysis of working postures (in this specific case using the so-called OWAS technique) studying assembly work on an automobile door. In this case we noted that the division of labour loss represents over 60% of the time consumption for assembly work. This analysis indicates that from an ergonomic point of view it is primarily worth studying what activities are included in the assembly work classified as OWAS work load level 2. This paper describes and illustrates methods and equipment developed consisting of a synchronized personal computer and video recorder. This promotes a design based on empirical data for specific cases through facilitating the collection and analysis of shop floor information about manual work and process efficiency of interest for the design of assembly systems.