Presentation

· Contributors · Organizations · Search Program · Flagged · Happening Now

Factors Affecting the Integration of Lift Assists in Automotive Assembly: Operator Perspectives

DescriptionAutomotive assembly workers face high risks of low back pain (LBP) due to frequent material handling (MH) tasks. Lift assists (LAs) potentially reduce these risks by offsetting gravitational forces while allowing operator control. However, integrating LAs remains challenging, and operator perspectives remain largely unexplored. We interviewed 16 automotive assembly operators to identify challenges, limitations, and preferences related to LA use. Content analysis revealed seven themes, grouped into two categories: Usability Factors and Concerns. Usability Factors included Hand Controls, Operational Functions, Physical Design, Workflow Efficiency, and Stakeholder Integration. Operators highlighted the need for fewer buttons with ergonomic controls, efficient maneuverability, and improved part manipulation. Training was critical for developing proficiency. Bulky and heavy LAs were criticized for increased physical demands, and poor maintenance disrupted workflows. Concerns included safety risks—such as falling payloads, pinch points, and obstruction hazards—and physical exertion in the back, shoulder, and lower limbs. Our findings suggest that improving LA usability requires early collaboration among engineers, ergonomists, designers, and operators, with emphasis on simple hand controls, smooth maneuverability, and light-weight designs. Comprehensive training and regular maintenance are also essential. Future research will quantify the effects of different LAs and task factors on physical demands and workflow efficiency.

Contributors