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Initiative

ElvalHalcor supports education and training in Industry 4.0 technologies through the Teaching Factory CC, promoting ergonomics and sustainability in the workplace.

ElvalHalcor supports education and training in Industry 4.0 technologies through the Teaching Factory CC, promoting ergonomics and sustainability in the workplace.
SUBMITTED FROM:

ELVALHALCOR

ElvalHalcor is a leading global manufacturer of aluminium and copper products. Today ElvalHalcor has a leading position in Europe in copper pipe production, and has established its presence in the aluminium rolling industry. The Company has over 80 years of experience and expertise, a powerfull production base with 15 factory units, and a commercial presence in over 100 countries, offering sustainability solutions and products in dynamically emerging markets such as packaging, transfers, construction and building, heating, cooling, air conditioning and renewable energy sources. ElvalHalcor is following a development, creating value for its stakeholders.  


www.elvalhalcor.com


Contact

Objective Action

ElvalHalcor supports the education and training of engineers and executives in Industry 4.0 technologies through the Teaching Factory CC (TF CC), enhancing their skills in areas such as Digital Manufacturing, Advanced Manufacturing, Mixed Reality & Sensors, Communications, and 5G.

TF CC is a non-profit organization that develops innovative approaches to education by connecting the academic community with the industry through the application of Industry 4.0 technologies to solve real industrial problems. ElvalHalcor is an active member of TF CC.

The integration of Industry 4.0 technologies into our factory represents a significant breakthrough in improving ergonomics and sustainability. We promote a policy of continuous improvement at all levels of our operations, focusing all our efforts and initiatives on enhancing conditions in the production process and preventing musculoskeletal problems. This not only serves the efficiency of our operations but also the well-being of our employees, fostering a healthy and sustainable work environment.

Thus, in the context of operator well-being, we conducted an ergonomic analysis during the phase change process through TF CC, based on skeletal data recorded by selected sensors.

 

Target Audience

- Engineers, executives, and students participate in the TF CC training programs.

- Production and H&S personnel.

 

Duration

6 months


Description

The ergonomic evaluation was performed in several steps:

Initially the evaluators made use of a software tool to record the operators body movements during the process. The software tool used records the human body joint angles and automatically calculates the REBA scoring for every frame captured.

The process was separated into five activities to group the data from the individual recordings. The recorded data were processed to evaluate the workstation using two methodologies, the REBA methodology and Job Screen methodology.

The REBA scoring methodology was used to perform a process screening and detect the activities with high REBA score during the process.

The activities with the highest REBA score were analyzed using Job Screen methodology to provide a more detailed visualization of the data, as well as to perform a comparison of the ergonomic analysis in case of process redesign for ergonomic improvement.


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Impact on Society

The Ergonomic Analysis was performed using two methodologies, REBA (Rapid Entire Body Assessment)

 and Job Screen, both methodologies classify the process in moderate or medium risk for MSD (Musculoskeletal Disorders). The analysis indicates that the upper body segments are the ones in stress.

One of the most critical actions performed by the operator during this process is the constant pick and place of the pulleys stored behind him.

A proposition for improving the ergonomics could be the installation of a basket/trolley cart for the operators to store all the pulleys there prior to the machine state change. With this solution the posture and the movement of the torso will be improved.



Initiative Location

ElvalHacor's Copper extrusion and Alloys division  - Halcor (in Copper tubes plant).

Oinofyta, Viotia.


Working with Organization

Teaching Factory – Competence Center


Workers Participation

Production, engineers, foremen, and operators. Specifically, operators of the spooler 6


Benefits for Οrganization

1. Acceleration of the speed of loading and unloading of the pulleys (returning them to the storage area)

2. Solving anthropometric issues (operator height and pulley storage level)

3. Protection of operators from torso and back injuries

Ergonomic evaluation aims to improve working conditions for individuals. By reducing body strain and enhancing ergonomic parameters, we aim to minimize injury risks and reassess process design, thereby improving occupational health and employee well-being. This directly benefits society by enhancing their quality of life and bolstering our social responsibility towards our workforce.




Connection with Global Goals







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