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Investigating Safety Awareness in Assembly Operations via Mixed Reality Technology

Israa Azzam,Souvik Das,Gaurav Nanda,Jose Garcia Bravo,F. Breidi

Published 2024 in IISE Transactions on Occupational Ergonomics and Human Factors

ABSTRACT

OCCUPATIONAL APPLICATIONS We investigated the impact of using Mixed Reality (MR) technology as a training tool to help trainees identify safety risks during machine assembly tasks, by analyzing their task completion efficiency and safety risk estimation capabilities. As proof-of-concept, an interactive MR module on hydraulic gripper assembly was designed and incorporated in fluid power laboratories to be tested with mechanical engineering technology students. The developed MR environment was evaluated using accident causation models. An environment analysis revealed smooth operation and minimal challenges. Incorporating interactive MR modules into training programs allows practitioners to provide trainees with hands-on experience in a simulated environment while identifying potential safety risks. Addressing limitations, such as simulating physical feedback more accurately, will be crucial for optimizing future safety training effectiveness using MR technology. TECHNICAL ABSTRACT Background: Safety awareness is critical in manufacturing, where assembly tasks pose risks due to complex equipment and ergonomic demands. Traditional training has limitations in preparing trainees for high-risk scenarios. Mixed Reality (MR) technology offers a solution by immersing users in realistic, interactive simulations that enhance safety training. Purpose: We explored users’ ability to identify safety risks when they receive training for manufacturing tasks in an MR environment, preparing them for real-life scenarios. Users’ perceptions of safety risks for an assembly task were examined within an MR setting, simulating the physical setup of a hydraulic gripper system. Methods: An interactive MR module on hydraulic gripper assembly was designed, incorporated into the fluid power course, and tested on 103 undergraduate students. The MR environment was analyzed using multiple accident causation models to identify safety risks associated with the assembly tasks. Survey questions were designed to study the impact of MR on safety awareness and investigate students’ safety perception during task completion. Survey responses were analyzed using thematic analysis and Natural Language Processing (NLP) approaches, particularly the Latent Dirichlet Allocation (LDA) Topic Model. Results: More than 75% of the students reported smooth operation and minimal physical challenges during task completion, regardless of their familiarity with the technology. The results also support the user-friendliness of MR settings, with minor discomfort reported by a few individuals (around 8%). Also, comparing safety risks identified in the MR environment vs. real-world assembly tasks revealed similarities, such as the potential for equipment damage and the importance of training and attention to detail. Conclusions: Our findings indicate that MR technology can improve safety awareness in assembly training. However, traditional safety protocols and ergonomic considerations remain essential for comprehensive safety training.

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