Safe workplace layout design by joint analysis of workers and material flows

In the era of industry 4.0 where human factor remains an essential part of operations systems, the layout of workspaces strongly determines the organisation of flow path and working conditions in a company. This article addresses the complexity of integrating safety considerations related to the movement of pedestrian workers within a workplace using existing layout design techniques. The proposed methodology is based on systematic layout planning framework and focuses on analyzing interactions flows between workspaces: workers and products flows. They are examined based on intensity, types, and travelled distances. An application in a bike assembly factory demonstrates reducing travel distances through optimized layout. The use case shows the benefits of considering both material an workers flows in order to create a safe and efficient working environment. (c) 2023 The Authors. Published by Elsevier B.V.