Integration of occupational health and safety in the facility layout planning,part II: design of the kitchen of a hospital

Facility layout design has an important effect on the performance of manufacturing systems. It intends to determine relative location of departments and machines within a plant. A good layout design must ensure that a set of criteria and objectives are met and optimised, e.g. area requirements, cost, communication and safety. The most common objective used in facility planning methods is to minimise the transportation cost. However, factors such as the plant safety, flexibility for future design changes, noise and aesthetics must be considered as well. In this paper, a case study is carried out to investigate the safety concerns in facility layout design. In this regard, a facility layout planning methodology, integrating occupational health and safety (OHS) is presented. This methodology considers transportation cost as well as safety in the facility design. By this means, OHS issues are considered at the design stage of the facility. In other words, this research demonstrates the improvements in the layout design by integrating safety aspects.     

A proposed occupational health and safety risk estimation tool for manufacturing systems

There are numerous hazards to be found in almost any workplace. Annually, millions of workers die, are injured or become ill as a result of these occupational hazards. Industrial machines are often involved in these occupational accidents. Because of the demands of regulatory compliance, and the potentially high cost in terms of human suffering and lost production, businesses should place particular emphasis on safety measures. Risk is defined as a combination of the probability of harm and the severity of its consequences. Generally, risk estimation involves examining the hazards associated with a situation or with the use of a machine. A large number of techniques have been proposed for risk estimation, and recent studies have revealed that some of them have serious flaws. The main objective of this paper is to develop a proposed risk assessment tool based on the findings of an earlier study. Our research results constitute a first step towards the integration of occupational health and safety (OHS) concerns into facility planning models which traditionally do not consider OHS. The proposed risk estimation tool is developed based on the characteristics, strengths and weaknesses of 31 existing risk estimation tools, and is then applied to 20 scenarios representing different hazardous situations. To evaluate the performance of the proposed tool, the results were compared with those of other risk estimation tools and confirmed its proposed ability to estimate risk relative to other risk estimation tools.     

Optimisation of facility layout design problem with safety and environmental factors by stochastic DEA and simulation approach

This article presents an integrated computer simulation–stochastic data envelopment analysis (SDEA) approach to deal with the job shop facility layout design problem (JSFLD) with stochastic outputs and safety and environmental factors. Stochastic outputs are defined as non-crisp operational and deterministic inputs. At first, feasible layout alternatives are generated under expert decision. Then, computer simulation network is used for performance modelling of each layout design. The outputs of simulation are average time-in-system, average queue length and average machine utilisation. Finally, SDEA is used with Lingo software for finding the optimum layout alternative amongst all feasible generated alternatives with respect to stochastic, safety and environmental indicators. The integrated approach of this study was more precise and efficient than previous studies with the stated outputs. The results have been verified and validated by principal component analysis. The unique features of this study are the ability of dealing with multiple inputs (including safety) and stochastic (including environmental) outputs. It also uses mathematical programming for optimum layout alternatives. Moreover, it is a practical tool and may be applied in real cases by considering safety and environmental aspects of the manufacturing process within JSFLD problems.     

Proposal of a risk-factor-based analytical approach for integrating occupational health and safety into project risk evaluation

Excluding occupational health and safety (OHS) from project management is no longer acceptable. Numerous industrial accidents have exposed the ineffectiveness of conventional risk evaluation methods as well as negligence of risk factors having major impact on the health and safety of workers and nearby residents. Lack of reliable and complete evaluations from the beginning of a project generates bad decisions that could end up threatening the very existence of an organization.     

Financial assessment of health and safety programmes in the workplace

In evaluating health and safety improvements for performance improvement, it is necessary to account for both the contributions of a healthy workforce and the resources required supporting it.

The Economic Assessment of the Work Environment (EAWE) is a financial framework that helps management forecast the financial benefits of health and safety implementations. The five-step process comprises (1) a health assessment to identify critical elements in the work environment, (2) an action plan to address gaps, (3) performance targets based on internal goals and external benchmarks, (4) transformation of the expected improvements in health and safety into expected performance outcomes, and (5) implementation in stages, starting from individual jobs to entire organisation.

EAWE offers a dynamic framework for corporate decision-makers when evaluating health and safety programmes. Further research should explore the bounds of EAWE across different types of organisations and the evolution of performance over time.     

Complexity and occupational safety and health prevention research

Society is changing too quickly, both in terms of a shift in the mentality of citizens or employees, and the increasingly frequent appearance of new technologies and new organizations with generally contracting time scales. The new complexity of the work environment modifies occupational safety and health (OSH) research, a paradigm which has to be revisited. Time pressure, complexity and a loss of scientific information have to be taken into account in order to maintain the confidence of the world of work with regard to the possible improvement of the quality of life at work supported by scientific knowledge.     

关于在气体行业建立质量、环境和职业安全健康一体化管理体系的探讨

介绍莱钢集团天元气体QEO管理体系建立过程中的整合和一体化工作,叙述QEO管理体系建立后的运行状况,总结天元气体在QEO管理体系建立、推行和实践中的一些经验和体会。     

A new relaxed flexible bay structure representation and particle swarm optimization for the unequal area facility layout problem

The facility layout problem (FLP) with unequal area departments is a very hard problem to be optimally solved. In this article, a hybrid particle swarm optimization (PSO) and local search approach is proposed to solve the FLP with unequal area departments. The flexible bay structure (FBS), which is a very common layout in manufacturing and retail facilities, is used. Furthermore, the FBS is relaxed by allowing empty spaces in bays, which results in more flexibility while assigning departments in bays. The proposed PSO approach is used to solve the FLP instances from the literature with varying sizes. The comparative results show that the PSO approach is very promising and able to find the previously known-optimal solutions in very short CPU times. In addition, new best solutions have been found for some test problems. Improvements have been achieved by allowing partially filled bays.     

Individual and occupational factors related to fatal occupational injuries: a case-control study

This study has been designed in order to identify factors increasing the risk of a fatal outcome when occupational accidents occur. The aim is to provide further evidence for the design and implementation of preventive measures in occupational settings. The Spanish Ministry of Labour registry of occupational injuries causing absence from work includes information on individual and occupational characteristics of injured workers and events. Registered fatal occupational injuries in 2001 (n = 539) were compared to a sample of non-fatal injuries in the same year (n = 3493). Risks for a fatal result of occupational injuries, adjusted by individual and occupational factors significantly associated, were obtained through logistic regression models. Compared to non-fatal injuries, fatal occupational injuries were mostly produced by trapping or by natural causes, mostly related to elevation and transport devices and power generators, and injured parts of body more frequently affected were head, multiple parts or internal organs. Adjusted analyses showed increased risk of fatality after an occupational injury for males (adjusted odds ratio aOR = 10.92; 95%CI 4.80–24.84) and temporary workers (aOR = 5.18; 95%CI 2.63–10.18), and the risk increased with age and with advancing hour of the work shift (p for trends <0.01). Injuries taking place out of the usual occupational setting (aOR = 2.85, 95%CI 2.27–3.59), or carrying out atypical tasks (aOR = 2.08; 95%CI 1.27–3.39) showed increased risks of a fatal result too, as occupational accidents in agricultural or construction companies. These data can help to select and define priorities for programmes aimed to prevent fatal consequences of occupational injuries.     

Unequal-area stochastic facility layout problems: solutions using improved covariance matrix adaptation evolution strategy,particle swarm optimisation,and genetic algorithm

Determining the locations of departments or machines in a shop floor is classified as a facility layout problem. This article studies unequal-area stochastic facility layout problems where the shapes of departments are fixed during the iteration of an algorithm and the product demands are stochastic with a known variance and expected value. These problems are non-deterministic polynomial-time hard and very complex, thus meta-heuristic algorithms and evolution strategies are needed to solve them. In this paper, an improved covariance matrix adaptation evolution strategy (CMA ES) was developed and its results were compared with those of two improved meta-heuristic algorithms (i.e. improved particle swarm optimisation [PSO] and genetic algorithm [GA]). In the three proposed algorithms, the swapping method and two local search techniques which altered the positions of departments were used to avoid local optima and to improve the quality of solutions for the problems. A real case and two problem instances were introduced to test the proposed algorithms. The results showed that the proposed CMA ES has found better layouts in contrast to the proposed PSO and GA.     

Dual-effects of core enterprise management and media attention on occupational health and safety of small and medium suppliers in China

This study examines the construction of an occupational health and safety (OHS) governance model for small- and medium-sized suppliers (SMSs) impacted by the dual effects of core enterprises' management and media attention. The objective of this research is to improve the social governance effect of SMSs' OHS. Drawing on evolutionary economics, an evolutionary game model with three main players—core enterprises, SMSs, and media—is established, and the conditions of each entity's evolutionary stability strategy are analyzed. The results show that the evolution trend for any party is closely related to the strategic choices of the other two parties. Further, a model for SMSs' OHS governance with focus on core enterprise management and media attention can be effectively built by reducing the costs of core enterprise management, enhancing the probability of accurate media reporting, decreasing the OHS input cost of SMSs, increasing the expected exposure returns of the media, and reducing the media's investigation cost. This study is the first to consider the important influence of core enterprises and the media on SMSs' OHS behavior, which bridges the research gap not only from a theoretical perspective, but also a practical one.     

Robotics in order picking: evaluating warehouse layouts for pick,place, and transport vehicle routing systems

Motivated by recent technological advances in mobile robotics, this paper explores a novel approach for warehouse order picking. In particular, this work considers two types of commercially available mobile robots – one that can grasp items from a shelf (a picker) and another (a transporter) that can quickly deliver all items from the pick list to the packing station. A new vehicle routing problem is defined which seeks to minimise the time to deliver all items from a pick list to the packing station, a problem termed the pick, place, and transport vehicle routing problem. A mixed integer linear programming formulation is developed to answer three related research questions. First, what combination of picker and transport robots is required to obtain performance exceeding traditional human-based picking operations? Second, how should the composition of the robot fleet be altered to affect the greatest performance improvements? Finally, what are the impacts of warehouse layout designs when coordinated mobile robots are deployed? An extensive numerical analysis reveals that, (1) increasing the number of cross aisles decreases system performance; (2) centrally located packing stations improve system performance; and (3) the average distance from each pick location to the packing station and the average distance between pick locations are effective metrics for identifying specific fleet modifications that are likely to yield system improvements.     

Bayesian methodology to estimate and update safety performance functions under limited data conditions: A sensitivity analysis

In road safety studies, decision makers must often cope with limited data conditions. In such circumstances, the maximum likelihood estimation (MLE), which relies on asymptotic theory, is unreliable and prone to bias. Moreover, it has been reported in the literature that (a) Bayesian estimates might be significantly biased when using non-informative prior distributions under limited data conditions, and that (b) the calibration of limited data is plausible when existing evidence in the form of proper priors is introduced into analyses. Although the Highway Safety Manual (2010) (HSM) and other research studies provide calibration and updating procedures, the data requirements can be very taxing. This paper presents a practical and sound Bayesian method to estimate and/or update safety performance function (SPF) parameters combining the information available from limited data with the SPF parameters reported in the HSM. The proposed Bayesian updating approach has the advantage of requiring fewer observations to get reliable estimates. This paper documents this procedure. The adopted technique is validated by conducting a sensitivity analysis through an extensive simulation study with 15 different models, which include various prior combinations. This sensitivity analysis contributes to our understanding of the comparative aspects of a large number of prior distributions. Furthermore, the proposed method contributes to unification of the Bayesian updating process for SPFs. The results demonstrate the accuracy of the developed methodology. Therefore, the suggested approach offers considerable promise as a methodological tool to estimate and/or update baseline SPFs and to evaluate the efficacy of road safety countermeasures under limited data conditions.     

Customer segmentation,allocation planning and order promising in make-to-stock production

Modern advanced planning systems offer the technical prerequisites for an allocation of “available-to-promise” (ATP) quantities—i.e. not yet reserved stock and planned production quantities—to different customer segments and for a real time promising of incoming customer orders (ATP consumption) respecting allocated quota. The basic idea of ATP allocation is to increase revenues by means of customer segmentation, as it has successfully been practiced in the airline industry. However, as far as manufacturing industries and make-to-stock production are concerned, it is unclear, whether, when, why and how much benefits actually arise. Using practical data of the lighting industry as an example, this paper reveals such potential benefits. Furthermore, it shows how the current practice of rule-based allocation and consumption can be improved by means of up-to-date demand information and changed customer segmentation. Deterministic linear programming models for ATP allocation and ATP consumption are proposed. Their application is tested in simulation runs using the lighting data. The results are compared with conventional real time order promising with(out) customer segmentation and with batch assignment of customer orders. This research shows that—also in make-to-stock manufacturing industries—customer segmentation can indeed improve profits substantially if customer heterogeneity is high enough and reliable information about ATP supply and customer demand is available. Surprisingly, the choice of an appropriate number of priority classes appears more important than the selection of the ATP consumption policy or the clustering method to be applied.     

Psychosocial safety climate as a lead indicator of workplace bullying and harassment, job resources, psychological health and employee engagement

Psychosocial safety climate (PSC) is defined as shared perceptions of organizational policies, practices and procedures for the protection of worker psychological health and safety, that stem largely from management practices. PSC theory extends the Job Demands–Resources (JD-R) framework and proposes that organizational level PSC determines work conditions and subsequently, psychological health problems and work engagement. Our sample was derived from the Australian Workplace Barometer project and comprised 30 organizations, and 220 employees. As expected, hierarchical linear modeling showed that organizational PSC was negatively associated with workplace bullying and harassment (demands) and in turn psychological health problems (health impairment path). PSC was also positively associated with work rewards (resources) and in turn work engagement (motivational path). Accordingly, we found that PSC triggered both the health impairment and motivational pathways, thus justifying extending the JD-R model in a multilevel way. Further we found that PSC, as an organization-based resource, moderated the positive relationship between bullying/harassment and psychological health problems, and the negative relationship between bullying/harassment and engagement. The findings provide evidence for a multilevel model of PSC as a lead indicator of workplace psychosocial hazards (high demands, low resources), psychological health and employee engagement, and as a potential moderator of psychosocial hazard effects. PSC is therefore an efficient target for primary and secondary intervention.     

Collection network design with capacity planning in reverse logistics: static and restricted-dynamic models

This study proposes two collection network design models that determine the locations and capacities of collection centres and the allocations of refuse at demand points to the opened collection centres: a single-period static model for time-invariant demands and a multi-period restricted-dynamic model for time-variant demands over a planning horizon. The capacities of collection centres are not given, but decision variables are used to obtain cost savings by minimizing surplus capacities. The maximum allowable distance between collection centres and demand points and the minimum recovery rates of collection centres are also considered. Two heuristics are proposed for each of the two problems after formulating them as integer programming models. Computational experiments were conducted on various test instances, and the results are reported. It is shown from the test results that the restricted-dynamic approach outperforms the static model significantly when the refuse demands are time variant. Finally, some managerial insights are derived.     

A review of production planning and control: the applicability of key concepts to the make-to-order industry

The paper reviews ‘classic approaches’ to Production Planning and Control (PPC) such as Kanban, Manufacturing Resource Planning (MRP II) and Theory of Constrains (TOC), and elaborates upon the emergence of techniques such as Workload Control (WLC), Constant Work In Process (CONWIP), Paired cell Overlapping Loops of Cards with Authorization (POLCA) and web- or e-based Supply Chain Management (SCM) solutions. A critical assessment of the approaches from the point of view of various sectors of the Make-To-Order (MTO) Industry is presented. The paper considers factors such as the importance of the customer enquiry stage, company size, degree of customization and shop floor configuration and shows them to play a large role in the applicability of planning and control concepts. The paper heightens the awareness of researchers and practitioners to the PPC options, aids managerial system selection decision-making, and highlights the importance of a clear implementation strategy. WLC emerges as the most effective Job Shop solution; whilst for other configurations there are several alternatives depending on individual company characteristics and objectives. The paper outlines key areas for future research, including the need for empirical research into the use of Workload Control in small and medium sized MTO companies.     

An integrated approach to determine the block layout,AGV flow path and the location of pick-up/delivery points in single-loop systems

Layout design and material handling system design are two of the major aspects of facility planning. Although both aspects directly influence each other, the classical approach to the layout design is carried out in two separate steps: in the first step the block layout, i.e. the location of the departments in the workshop, is constructed, and in the second step, the material handling system is designed. The separate optimisation of these two aspects of the problem leads to solutions that can be far from the global optimum. In this paper, we develop an integrated algorithm to design the facilities and material handling systems. We focus on single-loop AGV systems. The proposed algorithm determines the block layout, AGV single-loop flow path and pick-up delivery stations, simultaneously. The associated from–to chart and the area of departments are the principal inputs of the algorithm. The objective is minimising total material flow distance among all departments. The results of our computational experiments show the algorithm was coded using MATLAB 7.0, and that our integrated algorithm is more efficient in terms of both the objective function value and the runtime.     

An integrated multi-criteria Taguchi computer simulation-DEA approach for optimum maintenance policy and planning by incorporating learning effects

Modelling the maintenance activities could be complex and non-linear system which consists of different parameters. In this paper, a new approach for maintenance policy and planning problem is developed. First, maintenance activities are simulated by incorporating learning effects. Production and maintenance functions are estimated using historical data. Then, simulation is carried out for different scenarios which are combinations of periodic maintenance and different policies. Several outputs including machines and operators’ availability, reliability, efficiency and queue length are computed. Since the problem is multi-criteria, data envelopment analysis method is used to select the preferred policy. In order to show the applicability of the proposed approach, the data for a series production line is used and different scenarios with different policies are investigated. Since many scenarios are needed to be simulated, Taguchi orthogonal array design is used to reduce the number of scenarios. The proposed approach of this study would help managers to identify the preferred strategy considering and investigating various parameters and policies. This is the first study that introduces an integrated multi-criteria approach for optimum maintenance policy and planning.     

An integrated quality function deployment and capital budgeting methodology for occupational safety and health as a systems thinking approach: The case of the construction industry

In this paper, an integrated methodology for Quality Function Deployment (QFD) and a 0–1 knapsack model is proposed for occupational safety and health as a systems thinking approach. The House of Quality (HoQ) in QFD methodology is a systematic tool to consider the inter-relationships between two factors. In this paper, three HoQs are used to consider the interrelationships between tasks and hazards, hazards and events, and events and preventive/protective measures. The final priority weights of events are defined by considering their project-specific preliminary weights, probability of occurrence, and effects on the victim and the company. The priority weights of the preventive/protective measures obtained in the last HoQ are fed into a 0–1 knapsack model for the investment decision. Then, the selected preventive/protective measures can be adapted to the task design. The proposed step-by-step methodology can be applied to any stage of a project to design the workplace for occupational safety and health, and continuous improvement for safety is endorsed by the closed loop characteristic of the integrated methodology.