Industrial collaborative robotics is one of the main enabling technologies of Industry 4.0. Collaborative robots are innovative cyber-physical systems, which allow safe and efficient physical interactions with operators by combining typical machine strengths with inimitable human skills. One of the main uses of collaborative robots will be the support of humans in the most physically stressful activities through a reduction of work-related biomechanical overload, especially in manual assembly activities. The improvement of operators’ occupational work conditions and the development of human-centered and ergonomic production systems is one of the key points of the ongoing fourth industrial revolution. The factory of the future should focus on the implementation of adaptable, reconfigurable, and sustainable production systems, which consider the human as their core and valuable part. Strengthening actual assembly workstations by integrating smart automation solutions for the enhancement of operators’ occupational health and safety will be one of the main goals of the near future. In this paper, the transformation of a manual workstation for wire harness assembly into a collaborative and human-centered one is presented. The purpose of the work is to present a case study research for the design of a collaborative workstation to improve the operators’ physical ergonomics while keeping or increasing the level of productivity. Results demonstrate that the achieved solution provides valuable benefits for the operators’ working conditions as well as for the production performance of the companies. In particular, the biomechanical overload of the worker has been reduced by 12.0% for the right part and by 28% for the left part in terms of manual handling, and by 50% for the left part and by 57% for the right part in terms of working postures. In addition, a reduction of the cycle time of 12.3% has been achieved.

Industry 4.0 has attracted the attention of manufacturing companies over the past ten years. Despite efforts in research and knowledge transfer from research to practice, the introduction of Industry 4.0 concepts and technologies is still a major challenge for many companies, especially small and medium-sized enterprises (SMEs). Many of these SMEs have no overview of existing Industry 4.0 concepts and technologies, how they are implemented in their own companies, and which concepts and technologies should primarily be focused on future Industry 4.0 implementation measures. The aim of this research was to develop an assessment model for SMEs that is easy to apply, provides a clear overview of existing Industry 4.0 concepts, and supports SMEs in defining their individual strategy to introduce Industry 4.0 in their firm. The maturity level-based assessment tool presented in this work includes a catalog of 42 Industry 4.0 concepts and a norm strategy based on the results of the assessment to support SMEs in introducing the most promising concepts. For testing and validation purposes, the assessment model has been applied in a field study with 17 industrial companies.

Collaborative robots are revolutionising the manufacturing industry and the way workers perform their tasks. When designing shared workspaces between robots and humans, human factors and ergonomics are often overlooked. This study assessed the relationship between cognitive workload, workstation design, user acceptance and trust in collaborative robots. We combined subjective and objective data to evaluate the cognitive workload during an assembly task in three different scenarios in which we manipulated various features of the workstation and interaction modalities. Our results showed that participants experienced a reduction in cognitive workload in each of the three trials, indicating an improvement in cognitive performance. Additionally, we found that user acceptance predicted perceived stress across the trials but did not significantly impact the cognitive workload. Trust was not found to moderate the relationship between cognitive workload and perceived stress. This study has the potential to make a significant contribution to the field of collaborative assembly systems by providing valuable insights and helping to bridge the gap between researchers and practitioners. This study can potentially impact companies looking to improve safety, productivity and efficiency.

Within the framework of Industry 5.0, human factors are essential for enhancing the work conditions and well-being of operators interacting with even more advanced and smart manufacturing systems and machines and increasing production performances. Nevertheless, cognitive ergonomics is often underestimated when implementing advanced industrial human-robot interaction. Thus, this work aims to systematically update, develop, and validate guidelines to assist non-experts in the early stages of the design of anthropocentric and collaborative assembly applications by focusing on the main features that have positively influenced workers' cognitive responses. A methodology for structured development has been proposed. The draft guidelines have been created starting from the outcomes of a systematic and extended screening of the scientific literature. Preliminary validation has been carried out with the help of researchers working in the field. Inputs on comprehensibility and relevance have been gathered to enhance the guidelines. Lastly, a survey was used to examine in depth how international experts in different branches can interpret such guidelines. In total, 108 responders were asked to qualitatively and quantitatively evaluate the guideline's comprehensibility and provide general comments or suggestions for each guideline. Based on the survey's results, the guidelines have been validated and some have been reviewed and re-written in their final form. The present work highlights that integrating human factors into the design of collaborative applications can significantly bolster manufacturing operations' resilience through inclusivity and system adaptability by enhancing worker safety, ergonomics, and wellbeing.

Industrial collaborative robotics is an enabling technology and one of the main drivers of Industry 4.0 in industrial assembly. It allows a safe physical and human-machine interaction with the aim of improving flexibility, operator’s work conditions, and process performance at the same time. In this regard, collaborative assembly is one of the most interesting and useful applications of human-robot collaboration. Most of these systems arise from the re-design of existing manual assembly workstations. As a consequence, manufacturing companies need support for an efficient implementation of these systems. This work presents a systematical methodology for the design of human-centered and collaborative assembly systems starting from manual assembly workstations. In particular, it proposes a method for task scheduling identifying the optimal assembly cycle by considering the product and process main features as well as a given task allocation between the human and the robot. The use of the proposed methodology has been tested and validated in an industrial case study related to the assembly of a touch-screen cash register. Results show how the new assembly cycle allows a remarkable time reduction with respect to the manual cycle and a promising value in terms of payback period.