Optimization of ergonomic parameters in overhead arc welding using grey relational analysis

Area of Science:

• Ergonomics and Occupational Health
• Industrial Engineering
• Welding Technology

Background:

• Overhead arc welding poses significant physical demands, leading to work-related musculoskeletal disorders (WMSDs).
• Sustained awkward postures, repetitive motions, and inadequate workstations contribute to upper limb and lower back issues.
• These factors negatively impact worker performance, health, safety, and comfort.

Purpose of the Study:

• To optimize shoulder angle, elbow angle, and wrist position for overhead arc welding tasks.
• To minimize worker discomfort, shoulder pain, grip force, and task duration.
• To enhance overall worker well-being and productivity in demanding welding environments.

Main Methods:

• Utilized an L27 orthogonal array design to systematically evaluate ergonomic factors.
• Employed Grey Relational Analysis (GRA) to determine optimal factor combinations.
• Applied Analysis of Variance (ANOVA) to assess the significance of input factors and TOPSIS for validation.

Main Results:

• Identified optimal configuration: shoulder angle (115-125°), elbow angle (30-40°), and neutral wrist position (A2B3C2).
• ANOVA confirmed significant influence of shoulder angle, elbow angle, and wrist position on grip force, task efficiency, shoulder pain, and discomfort.
• Experimental validation confirmed the effectiveness of the identified optimal ergonomic settings.

Conclusions:

• Ergonomic optimization of joint angles and wrist posture is crucial for mitigating WMSDs in overhead arc welding.
• Findings provide practical insights for improving workstation design and task execution to enhance welder comfort and productivity.
• Further research is recommended to explore broader participant demographics, EMG analysis, and dynamic movement consistency.