TRW: automotive supplier – Industrial Health & Safety

trw
Empowerment of TRW workforce through active management of ergonomic risks
Smart shop-floor sensing and continuous privacy-preserving ergonomics data streams
On-the-spot feedback to the workforce to adapt progressively the behaviour for reduced ergonomic risk
Prevention department improves workplace design and task with advanced ergonomic risk analytics
TRW KPIs

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Description of the trial

The main objective of the TRW trial is the empowerment of TRW workforce through active management of ergonomic risks. The Ergonomic interventions are most common in industry. Current data shows that up to 80% of adult population is affected by an ergonomic risk and 40% of sufferers are out of work at some time in their life. As a result, the ergonomic interventions are the most profitable interventions (health and efficiency wise). Additionally, the EU workforce is aging, since the current 1:10 ratio on more than 55 years-old workers will turn in 1:4 in 2030. Therefore, the TRW use case is focused on the monitoring and assessment of the ergonomic risk that can affect to the blue-collar workers on the production lines, in order to perform effective prevention strategies. The traditional prevention strategies are not capable of customizing specific plans and current human-based surveillance is not completely effective. Current procedures and systems are not customized to the limitations or characteristics of the workers, so the results are not trustworthy in all the cases.

FITMAN TRW Trial fact sheet

ErgoPal

Innnovative service and functionalities

  • Real-time data collection through Kinect sensors

  • Smart shop-floor sensing and continuous privacy-preserving ergonomics data streams

  • Continuous data processing for advanced ergonomic risk analytics and detection

  • Real-time complex event processing

  • Web services and applications for corrective actions performance (e.g. web services for sending messages or warnings related to the risks detected)

  • On-the-spot feedback to the workforce to adapt progressively the behaviour for reduced ergonomic risk

Impact & benefits

TRW trial supports the introduction and acceptance of IoT technologies in the manufacturing industry in order to get the workplace of the future, providing the necessary balance between security concerns and privacy concerns. The implementation of monitoring technologies supports the innovative human-in-the-loop model, getting a participative approach for the workers’ empowerment solution. The main results of FITMAN demonstrate a competitive advantage both on the cost and efficiency of the business processes. On one hand, important reductions in the number of accidents and incidents in the factory (17% decrease) and in the human error during the planning of the prevention strategy (22% decrease) has been achieved. On the other hand, an increase of 95% in the risk detections and 50% in effective training sessions related to Health & Safety show the successful experience of the TRW trial.

TRW arch

Technical challenges

TRW has instantiated the Smart Factory Reference Architecture in order to develop an Active Ergonomic Risk Management process. The TRW Trial Platform is based on the Smart Factory Platform (GEs and SEs), as well as in the TRW legacy system, and new components and services developed for the trial (TSC). The TRW Trial Platform exploits the OSS components mainly related to IoT services, taking advantage of functionalities related to data gathering, complex event processing, context information management, and event information delivery, among others. As a result, the system monitors and collects real-time data of the skeleton and movements of the workers in the production line through Kinect sensors. It processes the data in order to detect “unsafety” events based on the defined rules (e.g. angles of the body or frequency of movements higher than the threshold values). In case of event detection, the different services or actions previously set up are delivered, e.g. messages or warnings are sent to the blue-collar workers and prevention technicians.

Business challenges

Human and organisational factors are still involved in almost 90% of all workplace accidents and incidents. Thus, it becomes necessary to develop new solutions that, taking benefit from the IoT technologies, improve the quality and comfort of the workforce. Indeed, TRW trial aims to develop a new generation of worker-centric safety management systems in order to reduce accidents and incidents in the production workplace through workers’ empowerment. The TRW use case is focused on the monitoring and assessment of the ergonomic risk that can affect to the blue-collar workers on the production lines, in order to perform effective prevention strategies. The traditional prevention strategies are not capable of customizing specific plans and current human-based surveillance is not completely effective. Current procedures and systems are not customized to the limitations or characteristics of the workers, so the results are not trustworthy in all the cases. Thus, the trial specially provides the following functionalities: i) real-time data collection through Kinect sensors, ii) continuous data processing for ergonomic risks detection, iii) events management, and iv) web services and applications for corrective actions performance (e.g. web services for sending messages or warnings related to the risks detected).

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IT PARTNER: Innovalia Association

Innovalia Association is an independent private Associated Research Lab. Innovalia, with more than 25 years of experience in technology-based product and service innovation with SMEs, assists SMEs in the development of ICT-based solutions in the areas of information security, software quality, M2M and mobile multimedia information services. Innovalia products and services address major telecom operators, broadcasters, transport infrastructure operators and manufacturing industries. Innovalia has an international presence, with premises in Spain – Basque Country, Madrid, Catalonia, Canary Island; Europe; Asia, Central and South America. The Innovalia Association is organised into three different Units: Information & Communication Technologies (ICT) Unit, Nanotechnology and Advanced Metrological Unit, Manufacturing and Knowledge Management Unit. Innovalia’s business activities broadly span the whole European market, the supply of RTD services, the networking of private and public companies with heavy emphasis on SMEs, SME collaboration activities and SME training. Among others, the activity sectors where the Innovalia Association focuses its activity include: Aeronautics and Space, Automotive, Electronics & Communications, SME Management, Industrial, Tourism and Entertainment, Metal-mechanics. Furthermore, Innovalia participates in the key ETPs, PPPs such as NanoFUTURES, MANUFUTURE, EUSPEN, EMVA, Photonics XXI, NetWorld2020, WWRF, ECSEL, ARTEMISA, ITEA and CELTIC. Innovalia sits the Industrial Research Advisory Group (IRAG) of the European Factories of the Future Research Association (EFFRA).

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END USER: TRW Automotive

TRW Automotive is a worldwide reference (Tier 1 provider) in manufacturing (machining, handling and assembly) of active and passive systems with an annual turnover that exceed 16.8 € billion. TRW Automotive is one of the world’s largest automotive suppliers, with 2011 sales of $16.2 billion. As leader in automotive safety, TRW produces active systems in braking, steering and suspensions and sophisticated occupant safety systems, as seat belts, airbags and steering wheels. TRW has over 60.000 employees worldwide, working in more than 185 locations and 26 countries. TRW plant in Pamplona is the Group reference plant, in terms of adoption of best of breed H&S practices and technologies. In this plant, TRW produces steering for tourism and industrial vehicles. The manufacturing process includes mechanising pieces and assembling steering gears. TRW's technological capacity is very high, as evidenced by the fact that the group entrusted TRW plant in Pamplona a very important part of the development and industrialization of different steering systems for different types of vehicles. The actual Pamplona’s staff number reaches 713 employees and its R&D department is composed by 26 engineers, which is divided in Product Engineering and Process Engineering. This department collaborates with external engineering companies that are required for each project.

TRW Automotive Espana