Balancing high operator's workload through a new job rotation approach: Application to an automotive assembly line

Reducing musculoskeletal disorder (MSD) risk factors and work monotony are the main reasons that persuade a manufacturing industry to apply job rotation in the workforce planning. This research aims to smooth the daily workload by designing an optimal sequence of job rotation using a mathematical model. The study consists of two main steps. The first is an ergonomic analysis of the workstations to evaluate the physical workload of different jobs. An in-house risk assessment method was used to identify physical workloads of each job. In the second step, a mathematical model was developed to schedule job rotation and optimize/balance the cumulative workload. Mixed integer programming is proposed to implement a platform for the ergonomic job rotation.