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doi:10.1016/j.cad.2013.01.007
938 J. Geng et al. / Computer-Aided Design 45 (2013) 937–949
2. Literature review to solve complex systems with multiple criteria. Meanwhile, the
consistency check can be unfavorable when a layer contains nu-
Recent publications relevant to this paper were mainly con- merous factors [43–46]. The entropy weight method calculates the
cerned with two research streams: virtual maintenance and main- integrative indicator with a large amount of information from each
tenance safety evaluation. In this section, relevant literature were element, whereas human ignorance will make it aimless [47,48].
summarized. The principle component analysis translates all the indicators into
For virtual maintenance, a considerable variety of studies have several independent integrative indicators; thus, the quantity and
been conducted since the late 1990s. In the recent years, the pre- the increase or decrease of indicators will affect the final result
dominance of virtual maintenance allowed more comprehensive [49,50]. The extension assessment method focuses on matter el-
applications, such as maintenance training [1,2], product design ement construction. However, the completeness of indicators and
[3,4], process simulation, and analysis [5–8]. Consequently, virtual the rationality of weights are the crux of the method [51,52]. The
maintenance can be used as a tool to simulate and analyze the synthetical index method has an uncomplicated principle and cal-
maintenance process to guide product design with virtual proto- culation, but is highly dependent on weight [53,54]. The factor
typing. analysis method creates several specific common factors based on
For maintenance safety evaluation, a great diversity of models the principle component analysis, whereas the common factors
was adopted during the past decades, including a techno-economic have little relevance with each other [55,56]. Table 1 shows the
model applied to the design and maintenance optimization based superior and inferior among the eight methods.
on safety analysis [9], a theoretical model used to carry out a sec-
ondary analysis of available data on maintenance accidents [10], 3. Development of the MSE model
various probabilistic risk analysis models for system safety as-
sessment [11–15], a model that combined a failure model and a
3.1. General framework
maintenance model for analyzing the impact of imperfect main-
tenance on system safety [16], and several other models in dif-
The proposed MSE model consists of three parts, namely, eval-
ferent domains [17–23]. Meanwhile, different approaches and
uation element, evaluation criteria, and evaluation method. Based
methods were proposed for safety management, analysis, and eval-
on existing maintainability design requirements, the evaluation
uation. For example, a systematic approach for the management
element selection should take full accountability of the feasibil-
of safety case change [24], an approach based on the effective
ity of launching evaluation in VME. Therefore, the selected ele-
coupling of genetic algorithms and Monte Carlo simulation for
ments can be analyzed with relating tools in VME. A hierarchical
the multi-objective optimization of nuclear safety systems [25],
structure of evaluation elements is constructed after confirmation.
a safety evaluation tool based on a detailed analysis of the safety
Evaluation criteria are the core of the whole framework; the es-
awarded by different types of measures [26], an evaluation system
tablishment of corresponding criteria to each element greatly in-
that used a combination of Analytic Hierarchy Process, decision
fluences the accuracy of evaluation results. Correlative description
rules and Bayesian tools belonging to operational research [27],
on maintainability design requirement of the selected elements
and a decision-making method for coal mining safety evaluation
is the main reference during evaluation criteria formulation. The
with linguistic values [28].
formulated criteria will grade the evaluation element according
However, few existing models were proposed for maintenance
to appeared maintenance safety condition. The analytic hierarchy
safety evaluation in VME. Moreover, safety evaluation needs to be
process (AHP) calculates the weight of each index due to the hierar-
carried out in a predictive way. If prevention is fully effective only
chical structure of evaluation element. In addition, the principle of
after the error has occurred, it is too late. One must identify risks
selecting snapshots for evaluation and confirming the safety level
to be evaluated and controlled before accidents happen [29,30].
for each element were introduced. The process of generating the
In addition, operational and maintenance activities are closely
MSE model is shown in Fig. 1.
related to each other to contribute to overall safety, which in turn
contributes to production quality and profit [31]. Hence, launching
MSE in VME is harmful to the improvement of product design in 3.2. Detailed description of the threefold in the MSE model
a predictive way during the early stages. Experience is extremely
vital during maintenance process [31]. However, the improvement 3.2.1. Evaluation element
solution from evaluation in VME will commendably guide the Personnel safety is an essential component in general maintain-
maintenance processes. ability design standards. Other aspects relating to personnel safety
Evaluation factor and criteria are highly important for the eval- in maintainability design standards should be considered when se-
uation of results [32,15,33]. Thus, the evaluation factor options lecting evaluation elements.
and criteria should be based on the problem being evaluated and Accessibility design affects the range of maintenance personnel
the scientific and practical relevance under the given circum- vision, the contact area of maintenance personnel, and the space
stances [34,35]. Previous industrial accidents provided predictive of maintenance personnel operation. If accessibility is poorly
information for safety factor confirmation. These information in- designed, maintenance personnel rely heavily on experience and
clude human factors [36–38] and mechanical risk factors [39]. Con- feelings when launching maintenance work, especially when
sequently, both should be concerned about when confirming VME facing the latest products. These scenarios always cause injury to
evaluation factors. the maintenance personnel with no preparation at all. For example,
Among the quantitative evaluation methods, eight common maintenance personnel will try every means to approach the
evaluation methods were compared to confirm a suitable one to maintenance pot with appropriate tools when the target lies on
the following proposed model in ascertaining evaluation index the critical edge of the contact area. In this situation, the target
weight. Gray evaluation method can launch a quantitative evalua- will most likely lose balance and fall from the platform. Therefore,
tion for qualitative factors, but subjectively when grading [40]. The availability is served as the first evaluation element, which consists
Fuzzy comprehension evaluation method qualifies the factors with of three sub-elements: visibility, reachability, and operation space.
a fuzzy relationship. The assurance of membership function is a Error proofing and marking designs influence the accuracy of
crucial part during application [41,42]. Analytical hierarchical pro- maintenance personnel in connecting, disassembling, installing,
cess effectively combines the quantitative and qualitative analysis filling, and so on. Errors objectively and inevitably exist in different
J. Geng et al. / Computer-Aided Design 45 (2013) 937–949 939
Table 1
The comparison among eight methods.
Evaluation method Superior Inferior
domains. Thus, error proofing design is fundamental to prevent 3.2.2. Evaluation criteria
maintenance personnel accidents. Personnel operation may tread Evaluation criteria are the fundamental basis to launch the
awry if two parts have similar shapes, but entirely distinct whole VME evaluation work. Corresponding contents related to
functions due to poor error proofing design, which may also result maintenance safety in maintainability design standards were con-
in accidents. For example, if the maintenance personnel hand is in sulted to confirm the evaluation criteria. The evaluation criteria
a dangerous area, the product maintenance can be disabled in this will be classified into three grades according to different embod-
condition. Furthermore, the correct making design can be carried iments with the help of relating VME analysis tools. Consequently,
out in striking position. Error proofing and marking designs are pertinent analysis tools in VME were explicated in detail, combined
affirmed as the second element, which naturally covers two child with their application in ranking the criteria. Various types of vir-
elements, namely, error proofing and making designs. tual simulation tolls have been applied in all walks of life and have
Ergonomic design concerns physical and psychological factors their own advantages. A summary of all the corresponding criteria
during the maintenance process. This design investigates the rela- is listed in Table 3.
tionship between body measurements and maintenance objects to
relieve discomfort and increase the efficiency of the maintenance 3.2.2.1. Criteria for accessibility design. (1) Visibility design.
personnel. Faulty ergonomic designs result in incompatible activi- Visibility design should guarantee the maintenance person-
ties and fatigue to the maintenance personnel, which is the hidden nel with a clear view of the target during the maintenance pro-
peril of accidents in several cases. Ergonomic design considers the cess. Hence it plays a central role in a man–machine system while
human body as the core during product design. Rational combina- manipulation [57,58]. Most frequently used displays should be
tion between product design and ergonomic design can effectively grouped together and placed in the optimum visual zone and ar-
minimize maintenance accidents; thus, ergonomic design is taken ranged in sequence within functional groups to provide a view-
as the third element. The Rapid Upper Limb Assessment (RULA) is ing flow from left-to-right or top-to-bottom, and vision models
an ergonomic technique that evaluates human exposures to pos- are obtained with a elliptical appearance in a computational way
tures, forces, and muscle activities. This technique shows the risk recently [59–63]. If the maintenance target is located in the best
level from continuous work. The ergonomic evaluation approach vision area, the maintenance personnel can clearly see the target
results in a risk score between one and seven, where higher scores and easily launch the work, as shown in Fig. 3. This result indicates
signify greater levels of apparent risks. RULA is adopted as the child a favorable visibility design; this situation is classified as rank A.
element of the third element ergonomic design. If the maintenance target is located in the widest vision area, al-
Physical harm occurs a lot during practical maintenance work. though the maintenance personnel have adjusted the posture, the
Heat, electrical, and mechanical injuries are examples of physical eyes may feel tired in focusing the obscene scene for a long time.
harm. Heat injury can decrease efficiency which leads to human This result illustrates a poor visibility design; this situation is clas-
error, electrical injury occurs from incorrect operation, whereas sified as rank B. If the maintenance target is located in the invisible
mechanical injury springs from shape corner and edge on equip- vision area even if the maintenance personnel adjusted the pos-
ments. Consequently, physical harm preventing design is consid- ture, they will not see the target at all and attempt to run the work
ered as the last element comprising the aforementioned injuries. A in terms of past experience. This situation shows a bad visibility
hierarchical structure of evaluation element is shown in Fig. 2. design and is classified as rank C.
940 J. Geng et al. / Computer-Aided Design 45 (2013) 937–949
(LUBA) [72], and rapid upper limb assessment (RULA) [73] are com-
monly used in ergonomic analysis. In addition, RULA is widely used
because of the simple and feasible procedure without interruption.
RULA launched the arm, wrist, neck trunk, and leg analysis, respec-
tively. RULA followed the predefined step-by-step procedure and
dealt with two analysis results to obtain a final score. The inter-
mediate scores, represented by a number and a color, were used
to calculate the final RULA score [73]. Table 2 indicates the score
range for each segment and the associated color. If the final score
is 1 or 2, the corresponding human limb will be green. This result
means an acceptable ergonomic design and the situation is clas-
sified as rank A. A final score of 3 or 4 and a yellow colored limb
means that the situation needs further investigation. A final score
of 5 or 6 and an orange colored limb means that the situation needs
further investigation and has to be changed soon. Both situations
Fig. 5. Collision detection between human and device. are classified as rank B. If the human limb turns red with a highest
final score of 7, the situation must be investigated and immediately
3.2.2.2. Criteria for error proofing design. Error proofing design changed for human safety. This situation is classified as rank C.
ensures the accomplishment of maintenance safety with an eye
on improving designs. Changing the sharp surface of connectors 3.2.2.4. Criteria for physical hurt prevention design. Prototype check
connected with cables that have the same radius but completely is employed to confirm the criteria for physical harm prevention
different functions, or selecting cables with distinguished colors which is the same criteria for error proofing design.
are examples of error proofing designs. However, the complexity of (1) Heat injury prevention design.
the product leads to the accuracy of dangerous position. Therefore, Essential heat protecting devices should be established to avoid
marking design is essential in this situation, such as direction contact between the skin and extremely hot or cold surfaces. Thus,
arrow, caution alert, tool warning, and so on. Prototype check is checking the position of heat protecting devices such as metal
effective especially for complex systems in the VME and discovers mesh and insulating panels and examining the contact between
an extraordinary number of defects. Thus, prototype check is the human limbs and product surfaces can be used to confirm the
main approach to confirm the criteria in this section. criteria for heat injury prevention designs. The total amount of heat
(1) Error proofing design. injury prevention is certain according to the given maintenance
The total amount of error proofing design is certain according process, so we take the percentage of heat injury prevention
to the given maintenance process, so we take the percentage of characters amount as the quantitative consideration for heat injury
error proofing design characters amount as the quantitative con- prevention design criteria. If necessary protective devices are
sideration for error proofing design criteria. After checking the appropriately set (the percentage of heat injury prevention design
corresponding position of the virtual prototype according main- characters amount is more than 90%) and no contact happens in the
tenance procedures, corresponding characters (the percentage of whole simulation, the condition is classified as rank A. Meanwhile,
error proofing design characters amount is more than 90%) in the if the protective devices are deficient (the percentage of heat
prototype can reasonably reflect the error proofing design and ef- injury prevention design characters amount is 10%–90%) or contact
fectively reduce accidents. Thus, this situation is classified as rank between human limbs and hazardous surfaces sometimes occur in
A. Error proofing designs in products are sometimes (the percent- the maintenance simulation, the situation is classified as rank B. If
age of error proofing design characters amount is 10%–90%) incom- few protective devices are present (the percentage of heat injury
pletely and irrationally devised; thus, this situation is classified as prevention design characters amount is less than 10%) or human
rank B. If few error proofing designs can be noted in the deserved limbs are always in contact with dangerous surfaces during the
prototype position (the percentage of error proofing design charac- simulation process, the situation is classified as rank C.
ters amount is less than 10%), accidents may happen if the mainte-
(2) Electrical injury prevention design.
nance personnel operate without too much experience. Thus, this
Most electrical equipments can cause electrical injuries because
situation is classified as rank C.
of the voltage, electric, and frequency together. Live working is
(2) Marking design. forbidden during maintenance processes to avoid electric shocks.
Similarly, prototype check is adapted to establish marking Electric cables should be distant from sharp-edged products. Both
design criteria, and we also take the percentage of marking design aspects should be concerned about confirming the electrical injury
characters amount as the quantitative consideration for marking prevention design criteria. If electricity is shut down by virtual
design criteria. A distinct and logical marking in the prototype humans in the simulation process and electricity cables during
can be noticed for accident prevention (the percentage of marking maintenance procedures probably wire away from sharp-edged
design characters amount is more than 90%). Thus, this situation objects, the situation is classified as rank A. If live working is
is classified as rank A. Meanwhile, confused and fragmentary
avoided, but electricity cables are in contact with sharp-edged
markings in the prototype present a marking design that requires
objects in several conditions, the situation is classified as rank
proof (the percentage of marking design characters amount is
B. Meanwhile, if live working is not avoided in the simulation
10%–90%); thus, is classified as rank B. A prototype with few
process whether or not electricity cables wire away, the situation
marking designs is classified as rank C (the percentage of marking
is classified as rank C because live working is extremely perilous.
design characters amount is less than 10%).
(3) Mechanical injury prevention design.
3.2.2.3. Criteria for ergonomic design. Ergonomic designs focus Mechanical injury covers several situations, including crush,
on the man–machine interface including physiological and psy- friction, stabbing, and so on. In this section, we focus on sharp-
chological factors to identify different defects in the design and edged objects exposed in the maintenance path that can affect
provide suggestions to ensure safe operation during the mainte- maintenance personnel safety. The total amount of mechanical in-
nance process. In general, ovako working-posture analyzing sys- jury prevention is certain according to the given maintenance pro-
tem (OWAS) [71], posture loading on the upper body assessment cess, so we take the percentage of mechanical injury prevention
942 J. Geng et al. / Computer-Aided Design 45 (2013) 937–949
Table 2
2RULA score.
Table 3
Summary of criteria to corresponding evaluation element.
Evaluation element Rank A Rank B Rank C
Criteria Corresponding Criteria Corresponding Criteria Corresponding
illustration embodiment in illustration embodiment in illustration embodiment in
VME VME VME
Visibility design Target could be Target locates in Target could be Target locates in Target could not Target locates
Accessibility
seen directly the best vision seen partly the widest vision be seen at all in the invisible
design
area because of area after vision area after
interruption adjusting adjusting
Reachability Maintenance Target locates in Maintenance Target locates Maintenance Target locates
design could reach the the envelope could not reach out of the personnel may just around the
target easily the target envelope try to approach boundary of
instinctively envelope
Operation space Maintenance Collision warning Maintenance Collision warning Maintenance Collision
design personnel could occurs hardly personnel occurs personnel always warning always
operate freely collides with sometimes collides with occurs
surroundings surroundings
sometimes
Error proofing Error proofing Safety accident Error proofing Safety accident Error proofing Safety accident Few error
design design could be reduced design is could be reduced design may happen proofing design
effectively reasonably in to a certain incompletely and probably if can be noted in
prototype extent irrationally in maintenance deserved
prototype personnel position of
operates without prototype
too much
experience
Marking design Distinct and Confused and Few marking
logical marking fragmentary design could be
marking found
Ergonomic RULA Acceptable Final score is 1 or Ergonomic Final score is 3–6 Ergonomic Final score is 7
design ergonomic 2 with green design need to be with yellow or design need to be or higher with
design color investigated brown investigated red color
further and further and
change soon change
immediately
Physical hurt Heat injury Necessary protecting devise is set Protecting devise is deficient or human Few protecting devise could be
preventing preventing appropriately and no contact happens limb contact with the dangerous discovered or human limb always
design design between human limb and dangerous surface sometimes contact with dangerous surface
surface
Electrical injury Electric power is shut down in Live working is avoided but electricity Live working is not avoided no
preventing simulation and corresponding cables contact with sharp edge in matter electricity cables wire
design electricity cables wire away from several conditions probably or not
sharp edge probably
Mechanical Sharp edge is chamfered Chamfer is missing in some necessary Few chamfer occurred
injury preventing comprehensively and precisely position
design
characters amount as the quantitative consideration for mechan- design characters amount is less than 10%), this situation is classi-
ical injury prevention design criteria. If sharp-edged objects are fied as rank C.
comprehensively and precisely chamfered (the percentage of me-
chanical injury prevention design characters amount is more than 3.2.3. Evaluation method
90%), the situation is classified as rank A. Moreover, if chamfer is Evaluation method focuses on three relevant issues: selecting
missing in several necessary positions (the percentage of mechan- snapshots for evaluation; judging the safety level for each element;
ical injury prevention design characters amount is 10%–90%), the and confirming factor weights for calculation.
situation is classified as rank B. If few chamfer in the product are The snapshots used for evaluation are determined by main-
potential hazards (the percentage of mechanical injury prevention tenance spots during a maintenance process. The maintenance
J. Geng et al. / Computer-Aided Design 45 (2013) 937–949 943
similarity in that it focuses on hand or arm activities from main- Intensity of importance Verbal scale
tenance personnel. Other body parts are relatively fixed, and all 1 Equal importance
the maintenance operation spots occupy most of the whole main- 3 Weak importance of one over another
tenance time. Consequently, maintenance spots are selected as the 5 Essential or strong importance
snapshots are used for evaluation to comprehensively and system- 7 Demonstrated importance
9 Absolute importance
atically detect safety design flaws. Furthermore, a designer needs 2, 4, 6, 8 Intermediate value between the two adjacent
to confirm several main spots according to maintenance schedules judgment
or maintenance simulations, such as disassembling bolts, lifting
hatch covers, disconnecting cables, removing device, and so on.
Table 5
After selecting snapshots for evaluation, the safety level of each
RI value.
element is judged according to human operation analysis or pro-
n 1 2 3 4 5 6 7 8 9
totype checks of all the snapshots from the maintenance process.
RI 0 0 0.58 0.90 1.12 1.24 1.32 1.41 1.45
For each element, the selected snapshots provide different results
to reflect the corresponding product design characters. The worse
result will be treated as the safety level of each element because
The corresponding RI value is listed in Table 5.
safety accident can occur from any micro manipulation. None of
Calculate CR with Eq. (5).
the design limitation should be ignored. In this way, designers can
focus on the design flaws that reduce product safety level directly CI
and rapidly. CR = . (5)
RI
According to the aforementioned established evaluation model,
If CR ≤ 0.10, the consistency is considered acceptable [81].
the analytical hierarchical process (AHP) is adapted to confirm
(4) Suppose a goal has m criteria A1 , A2 , . . . , Am with their weights
factor weight with information from actual experience. AHP has
a1 , a2 , . . . , am , and Aj (0 < j < m) has n subcriteria
various applications since its introduction by Saaty [43–46]. Nu-
B1 , B2 , . . . , Bn with the weights b1j , b2j , . . . , bnj , Eq. (6) is in-
merous applications of this method can be found in maintenance,
troduced to obtain the weight of level B to the goal.
such as confirming the rational weight of importance of mainte-
nance priority ranking factors [74], selecting corresponding main- m
tenance policy [75], and prioritizing maintenance activities [76]. bi = bij aj , i = 1 , 2 , . . . , n. (6)
The AHP is illustrated briefly as follows. j =1
(1) Construct a hierarchy after analyzing the relationship between Calculate the total CR with Eq. (7).
the goal, criteria, and subcriteria. Thus, a flexible hierarchy can (5)
be constructed reasonably according to the problem that needs
m
to be solved.
CI(j)aj
(2) Determine the relative importance of the alternatives with re- j =1
gard to each of the criteria or between two criteria, and gen- CR = m
. (7)
erate an n-by-n matrix A = (aij )n×n to represent the qualified RI(j)aj
judgment on pairs [77], where aij is the relative importance of j =1
No heat source exists in APU and no electronic operation Consequently, the consistency is considered acceptable.
occurs in the simulation. Thus, heat injury prevention design and Similarly, for matrix B1 , B2 , B3 , B4
electronic injury prevention design are configured as rank B to CR1 = 0.0462 < 0.1
represent an average design. All the sharp edges on the equipment
and frame around the operation spot and all the contact on the CR2 = 0 < 0.1
support device are designed without chamber, as shown in Fig. 12. CR3 = 0 < 0.1
Thus, mechanical harm analysis is evaluated as rank C. CR4 = 0.0158 < 0.1.
J. Geng et al. / Computer-Aided Design 45 (2013) 937–949 945
Consequently, the consistency is considered acceptable. In this paper, a maintenance safety evaluation model applicable
The maintenance safety analysis is summarized in Table 6. to the virtual maintenance environment was proposed to evaluate
J. Geng et al. / Computer-Aided Design 45 (2013) 937–949 947
maintenance safety design with the help of maintenance simula- the problem. Second, safety analysis at each snapshot aims at
tion and prototype check. The presented evaluation model includes the relatively static virtual human, whereas the postural variation
evaluation element, evaluation criteria, and evaluation methodol- happens obviously during maintenance process. Thus, the amount
ogy after fully considering the characters and framework of the vir- of slight variation affecting the final result of each snapshot should
tual maintenance environment. The advantages of the proposed be considered. Third, the dummy in VME is nude and does not
system are summarized as follows: (1) Launch the maintenance reflect the restrictions clothing impose, such as reachability and
safety evaluation in the product design stage to improve the main- ergonomics. If clothing is considered, partial analysis will slightly
tenance safety design and decrease the possibility of accidents. vibrate. Recent research has focused on novel product prototypes
(2) Maintenance safety evaluation work performed intuitively via from different domains in the laboratory. Parts of those users have
virtual maintenance technology. (3) Combine static check and dy- provided positive feedback for improving the maintenance safety
namic simulation from maximizing prototype to determine the design against similar products. Safety maintenance requirement
design flaws. (4) Evaluate the qualitative maintenance element is essential, and more feedback information including past accident
quantitatively with AHP to provide more purposeful advice for de- records is needed to validate the proposed method in this
sign improvement. paper. Ongoing and future work will focus on improvements
However, several limitations exist in the proposed evaluation including virtual manikin anthropometry, slight variation at
model. First, only the 50th percentile anthropometric data was each snapshot, and clothing consideration. Furthermore, more
used with human models. Thus, the diversity of virtual dummy evaluation elements in the virtual maintenance environment and
anthropometry was ignored. Several amendment methods or corresponding criteria will be added to the existing model if
appropriate multivariate data and techniques are needed to solve possible.
948 J. Geng et al. / Computer-Aided Design 45 (2013) 937–949
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