A case study of serial‐flow car disassembly: Ergonomics, productivity and potential system performance

A recent European Union (EU) directive increases demands on car recycling. Thus, present craft‐type disassembly systems need reconfiguration in order to be more efficient. A line‐based system tested in the Netherlands was investigated regarding system performance and ergonomics. The system had reduced performance compared to the design specifications due to such factors as system losses, operator inexperience, and teamwork deficiencies. Operators' peak low back loads were lower than in Swedish craft‐type systems. Direct, value‐adding work comprised 30% of the workday, compared to about 70% in the Swedish manufacturing industry. Alternative system configurations were simulated and discussed using a novel combination of flow and human simulations. For example, a smaller variation in cycle time implied higher output in number of cars per week and larger operator cumulative loading on the low back. In all models the cumulative load was high compared to the loads previously recorded in assembly work.