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Research Paper Human Factors in Industry 4.0
Research Paper Human Factors in Industry 4.0
Control
9th IFAC
Control
Berlin, Conference
Germany, on Manufacturing
August 28-30, 2019 Modelling, Management and
9th IFAC
Control
Berlin,
9th IFAC
Conference
Germany, August
Conference on 28-30, 2019 Available
on Manufacturing
Manufacturing
online
Modelling, at www.sciencedirect.com
Management and
Modelling, Management and
Control
Berlin, Germany, August 28-30, 2019
Control
Berlin, Germany, August 28-30, 2019
Berlin, Germany, August 28-30, 2019 ScienceDirect
IFAC PapersOnLine
Exploring human 52-13 (2019) 2183–2188
factors in Logistics 4.0:
Exploring human factors in Logistics 4.0:
empirical
Exploring evidence
human frominaLogistics
factors case study 4.0:
empirical
Exploring
Exploring evidence
human
human fromin
factors
factors inaLogistics
case study
Logistics 4.0:
4.0:
empirical evidence from a case study
Chiaraempirical evidence
Cimini* Alexandra from
Lagorio* a
Fabianacase study
Pirola* Roberto Pinto*
Chiaraempirical evidence
Cimini* Alexandra from
Lagorio* a case
Fabiana study
Pirola* Roberto Pinto*
Chiara Cimini* Alexandra Lagorio* Fabiana Pirola* Roberto Pinto*
Chiara Cimini* Alexandra Lagorio* Fabiana Pirola* Roberto Pinto*
*Department of Management, Chiara Cimini* Alexandra
Information andLagorio*
IndustrialFabiana
Engineering,Pirola* RobertoofPinto*
University Bergamo, Italy (e-mail:
*Department of Management, Information and Industrial Engineering, University of Bergamo, Italy (e-mail:
chiara.cimini@unibg.it, alexandra.lagorio@unibg.it, fabiana.pirola@unibg.it, roberto.pinto@unibg.it).
*Department of Management,
chiara.cimini@unibg.it, Information and Industrialfabiana.pirola@unibg.it,
alexandra.lagorio@unibg.it, Engineering, Universityroberto.pinto@unibg.it).
of Bergamo, Italy (e-mail:
*Department of Management,
chiara.cimini@unibg.it, Information and Industrialfabiana.pirola@unibg.it,
alexandra.lagorio@unibg.it, Engineering, Universityroberto.pinto@unibg.it).
of Bergamo, Italy (e-mail:
*Department of Management, Information and Industrial Engineering, University of Bergamo, Italy (e-mail:
chiara.cimini@unibg.it, alexandra.lagorio@unibg.it, fabiana.pirola@unibg.it, roberto.pinto@unibg.it).
chiara.cimini@unibg.it,
Abstract: Nowadays, thealexandra.lagorio@unibg.it,
terms Smart Logistics and Logistics fabiana.pirola@unibg.it,
4.0 are used to represent roberto.pinto@unibg.it).
the Industry 4.0
Abstract:
technology-basedNowadays, the terms
application in Smart
the Logistics
field of and Logistics
logistics. The 4.0 are used
introduction of to represent
technology in the Industry
logistics 4.0
affects
Abstract:
technology-basedNowadays, the terms
application in Smart
the Logistics
field of and Logistics
logistics. The 4.0 are used
introduction of to represent
technology in the Industry
logistics 4.0
affects
significantly
Abstract:
technology-based the work
Nowadays, of
theoperators,
application terms in the opening
Smartfield of new
Logistics evolution
and Logistics
logistics. The scenarios
4.0 are
introduction andusedofoffering several
to represent
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the Industry
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4.0
affects
significantly
Abstract:
change of Nowadays,
the the workrole
human theoperators,
of terms
in Smart
logistics. Logistics
opening
Starting new fromanda Logistics
evolution
literature 4.0 are
scenarios
analysis, andused to
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paper several
aims atthe Industry 4.0
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new The
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Keywords: (International
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Keywords: discussing
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Keywords:
decision support Industry
systems 4.0,inLogistics
manufacturing,in manufacturing,
Human operator Intelligent
support manufacturing systems, Intelligent
Keywords:
decision Industry
support systems 4.0,inLogistics
manufacturing,in manufacturing,
Human operatorIntelligent
support manufacturing systems, Intelligent
Keywords: Industry 4.0, Logistics in manufacturing, Intelligent manufacturing systems, Intelligent
decision support systems in manufacturing, Human operator multiplesupport
activities, human work still turns out to be essential,
decision support systems in manufacturing, Human operator support
1. INTRODUCTION multiple activities, human work still turns out to be essential,
1. INTRODUCTION and would
multiple not be human
activities, substituted workentirely
still turns by outtechnology within
to be essential,
The advent of Industry 4.0 in the manufacturing landscape
1. INTRODUCTION and
the would
future not be
(Jäger & substituted
Ranz, 2014; entirely
Mital & by technology
Pennathur, within
2004).
multiple
and would activities,
not be human
substituted workentirely
still turns by out to be essential,
technology within
The advent
pavedadvent
the wayof 1.
Industry INTRODUCTION
4.0
for1.breakthroughin the manufacturing
innovations inlandscapelandscape
logistics the multiple
the future activities,
(Jäger & human
Ranz, work
2014; still
Mital turns
& out
Pennathur,to be essential,
2004).
The of Industry INTRODUCTION
4.0 in the manufacturing andfuture
would(Jäger not be & substituted
Ranz, 2014;entirely Mital &by technology
Pennathur, within
2004).
paved the way
(Witkowski,
The advent
paved the 2017). for Many
of Industry
way for
breakthrough
technologies innovations
4.0 in the manufacturing
breakthrough have
innovations in to be and
in logistics
started
landscape
logistics the
wouldreasons,
For future
these not be
(Jäger & Ranz,
substituted
assessing 2014;
entirely
the role&of
Mital
by technology
the
Pennathur,operator within
in the
2004).
The advent
(Witkowski,
implemented, of Industry
2017).
and a Many 4.0
“logistic in the
technologies manufacturing
transformation” have is landscape
started
occurring to be
to the
For
new future
these (Jäger
Industryreasons, &
4.0 Ranz,
assessing 2014;
context the Mital
is role &ofPennathur,
essential the operator
for 2004).
an in the
active
paved the
(Witkowski, way
2017). for breakthrough
Many technologies innovations in
haveisstarted logistics
to be For these reasons, assessing the role of the for operator in the
paved the
implemented, wayand
align logistics2017). for
a breakthrough
“logistic
processes innovations
transformation” in logistics
occurring to new Industry 4.0 context is essential an active
(Witkowski,
implemented, and Manytotechnologies
a “logistic the requirements
transformation” of thetonew
haveisstarted
occurring be
to new transformation
For these
Industryreasons,to4.0Logistics
assessing
context 4.0.theis role of the for
essential operator an in the
active
(Witkowski,
align logistics
Industry 4.0 2017).
processes
production Manyto technologies
the requirements
context (Maslarić,have Nikoličić,
started
of thetonew be
& For these
transformation reasons, assessing
to Logistics 4.0.the role of the operator in the
implemented,
align logistics and a “logistic
processes to transformation”
the requirements is occurring
of the new to new Industry
transformation 4.0
to4.0 context
Logistics is essential
4.0. is essential for an activefor an active
implemented,
Industry 4.0 and a
production“logistic
Nowadays, transformation”
context
the (Maslarić, is occurring
Nikoličić, to
& new Industry context
Mirčetić,
align
Industry 2016).
logistics
4.0 processes
production to the terms
context Smart Logistics
requirements
(Maslarić, of the new
Nikoličić, and This paper provides
& transformation to Logistics insights
4.0. on the work of logistics
align logistics
Mirčetić,
Logistics 2016).
4.0 areprocesses
Nowadays,
used to to
depict thethe
the requirements
terms
Industry of
Smart4.0Logistics the new
technology- and transformation
This paper
operators after to
provides
the Logistics 4.0. onIndustry
insights
introduction the work of logistics
Industry
Mirčetić,
Industry
Logistics 2016).
4.0
production
Nowadays,
production
are used
context
thethe
context
to field
depict
(Maslarić,
terms
Industry
(Maslarić,
Nikoličić,
Smart4.0Logistics
technology-
Nikoličić,
&
and
& This paper
operators after provides
the insights of
introduction onIndustry
of the work 4.0 technologies
4.0 of logistics
technologies
based application
Mirčetić, 4.0
Logistics 2016). in
are used the
Nowadays,
to field
depict of
thethe logistics
terms (Müller
Smart4.0Logistics
Industry & Voigt,
technology- supporting
and operators
This paper operations.
provides Exploiting
insights both
onIndustry
the work knowledgeof logisticsfrom
based application
Mirčetić, 2016). Nowadays,
in the theof terms
logistics Smart Logistics
(Müller & Voigt, and This paper
supporting after the introduction
provides
operations. insights
Exploiting of
on both the work4.0 technologies
knowledgeofcase logistics
from
2018).
based Several
Logistics 4.0
application functional
are used
in the to areas
depict ofthemanufacturing
Industry 4.0 logistics
technology- are literature
operators review
after theand practical
introduction insights
of from
Industry a real
4.0 technologiesstudy
Logistics
2018).
affected 4.0changes
Several
by are used
functional to field
and depict
areas of
ofthe
improvements,
logistics
Industry
manufacturing (Müller
such
& Voigt,
4.0aslogistics
technology-
warehouse are supporting
operators
literature
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operations.
after
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the the Exploiting
andintroduction
opportunities practical offered ofby
insights both
Industry
from
the
knowledge
shifta4.0
real
to technologies
thecase from
study
Industry
based application
2018). Several in the field
functional areas of
of logistics
manufacturing (Müller & Voigt, supportingreview operations. Exploiting both knowledge from
based application
affected
management,by changes in and
the field
transportation of
improvements,
and logistics such aslogistics
(Müller &
warehouse are literature
Voigt, supporting
analysis, the operations.and practical
opportunities Exploitinginsights
offered by bothfrom
the a real
knowledge
shift case
tologistics
the study
from
Industry
2018). Several
affected by functional
changes and areas ofresource
improvements, manufacturingplanning
such as (Barreto,
logistics
warehouse 4.0
are analysis, paradigm
literature review
the toandsupport
opportunities practical a insights
offered human-centric
by from
the shifta real
to thecase are
study
Industry
2018).
Amaral, Several
management,& functional
transportation
Pereira, 2017). areas
and of
Technology manufacturing
resource planning
supports logistics
both (Barreto,
physicalare literature
4.0 review
paradigm
explored and toand
discussed. practical
support a insights from
human-centric a real case
logistics study
are
affected
management,by changes and
transportation improvements,
and resource such as
planning warehouse
(Barreto, analysis,
4.0 the opportunities
paradigm to supportoffered by the shift tologistics
a human-centric the Industry are
affected
Amaral,
logistics &by
& changes
Pereira,
processes, and
2017). improvements,
Technology
and information such
supports
exchange as
bothwarehouse
physical
and (Barreto,
decision analysis,
explored the
and opportunities
discussed. offered by the shift to the Industry
management,
Amaral, transportation
Pereira, 2017). and resource
Technology planning
supports both physical explored4.0 paradigmand discussed.to support a human-centric logistics are
management,
logistics
systems (Timm transportation
processes,
& and 2015).
Lorig, and resource
information exchangeplanningand (Barreto,
decision 4.0 paradigm to support a human-centric logistics are
Amaral,
logistics & Pereira,
processes, 2017). Technology
and 2015).
information supports
exchange both physical
and decision The paper
explored and is structured
discussed. as follows. In Section 2, a literature
Amaral,
systems &
(Timm
Traditionally, Pereira,
& 2017).
Lorig,
logistics Technology
processes are supports both
recognised physical explored
The paper and is discussed.
structured as follows.
to be overview is presented, including two parts. First, the role of In Section 2, a literature
logistics
systems processes,
(Timm & Lorig,and 2015).
information exchange and decision
logistics
affected processes,
Traditionally,
by logistics
several andissues
information
processesthat exchange
are recognised
directly influence to be The
and decision paperisispresented,
overview structuredincludingas follows. two Inparts.
Section 2, atheliterature
First, role of
systems
affected
(Timm
Traditionally,
systems (Timm
by
&
&
Lorig,
logistics
Lorig,
several
2015).
processes
2015).
issues that are recognised
directly influence to the
the
operators
The
be overview
The
paperis
paper
operators
inispresented,
inis
traditional
structuredincluding
structured
traditional
logistics
as follows.
as follows.
logistics
is In
two
is
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In
Section
parts.
Section
investigated,
2, in
First,
2, a
in
order
atheliterature
role of
literature
order
to
to
performance
Traditionally,
affected of
logistics
by several companies
processes
issues (Strandhagen,
are recognised
that (Strandhagen,
directly influence Alfnes,
to be
the underline
overview the
is main
presented, areas and
including issues
two of the
parts. human
First, the work
role in
of
Traditionally,
performance
Strandhagen, & logistics processes
ofVallandingham,
companies are
2017). recognised
Among them, to the
Alfnes,be operators
overview
underline in
is
the traditional
presented,
main areas logistics
including
and is investigated,
two
issues parts.
of the First,
human inthe order
role
work to
of
in
affected by several
performance issues that (Strandhagen,
ofVallandingham,
companies directly influence Alfnes, manufacturing
operators in thetraditionallogistics.
areaslogistics Second, the
is investigated, Industry
in order 4.0
to
affected
Strandhagen,
human by &
factor several issues asthatone
isofVallandingham,
considered directly
2017). Among
of the influence
them,
mostthem, relevantthe underline
operators
manufacturing in main
traditional
logistics. andSecond,
logistics issues of the
the human
is investigated,
is discussed, in
Industry
in
work4.0
order
order
in
to
to
performance
Strandhagen, & companies (Strandhagen,
2017). Among Alfnes,
the technologies’
underline
manufacturing the application
main areas
logistics. in
andlogistics
issues
Second, of the
the human
Industry work in
4.0
performance
human factor
uncertainties isof
perceived companies
considered by as one (Strandhagen,
logisticians of the
in most
the Alfnes,
relevant
industrial underline
technologies’
provide a the main
application
background areas
on and
in
the issues
logistics
most of
is the
discussed,
interesting human in
functional work
order
areasin
to
Strandhagen,
human factor && Vallandingham,
is Vallandingham,
considered as one 2017). Among
of the them,
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technologies’ logistics.in logistics
Second,is discussed,
the Industry in order 4.0
to
Strandhagen,
uncertainties
processes perceived
(Nilsson, by
2006).by logisticians 2017).
logisticians Among
in the industrialthe manufacturing
provide a background logistics.
on the Second,
most the
interesting Industry
functional 4.0
areas
human factor
uncertainties is considered
perceived as one of the relevant affected
mostindustrial
in the aby
technologies’ technological
application inadvances.
logistics Indiscussed,
is Section 3,inaorder
deeper to
human
processes factor is considered
(Nilsson, 2006). as one of the most relevant provide affected by
technologies’ background
technological
application on the most interesting
inadvances.
logistics is
Indiscussed,
Section functional
inaorderareas
3,developed,
deeper to
uncertainties
processes perceived
(Nilsson, 2006). by logisticians in the industrial discussion
provide
affected aby about
background Operator
technological on the 4.0
most
advances. in Logistics
interesting
In Section is
functional
3, a areas
deeper
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Human factors perceived
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defined as the “scientific discipline affected industrial provide
discussion a background
about on
Operator the most
4.0 ininteresting
Logistics functional
is areas
developed,
processes (Nilsson, focusing by
discussion on about
how tasks
technological would
Operator be divided
advances.
4.0 In between
in LogisticsSectionis humans
3,developed,
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processes
Human (Nilsson,
factors are 2006).
defined as theof“scientific discipline affected
focusing by
on technological
how tasks would advances.
be divided In between
Section 3, athe
humans deeper
and
concerned
Human with
factors the
are understanding
defined as theof“scientific interactions among machines
discussion in smart
about manufacturing
Operator 4.0 inlogistics,
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Human factors
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at providing logistics. about
real examples At the of
the
cognitive,
order
work perceptual
to optimize
(Grosse, Calzavara, and Glock,
human psychosocial
well-being
& aspects of the
and overall
Sgarbossa, 2017). human
system evidences
Among same time,
implication areof
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thecase aiming
study
introduction at
offersof providing
some insights
Industry real technologies
4.0 examples
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psychosocial elements,aspectssuchof as
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same time,4.0 technologies’
the case study applications
offers some in logistics.
insights At the
about the
work (Grosse,
performance”
them, human and
behaviourinclude
Calzavara, several
Glock, & elements,
Sgarbossa, such as
2017). physical,
Among Industry
implication 4.0 oftechnologies’
the introduction of
applications Industry in 4.0 At
technologies
logistics. the
cognitive,
work (Grosse,perceptual
Calzavara, andand decision making
psychosocial
Glock, aspects
& Sgarbossa,
areoftwo
therelevant
2017). on human
human implication
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of casewhich study
introductionareoffers
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of Industry the lastabout
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aspects, perceptual
that behaviour
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significantly aspects
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logistics areofmanagement
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Section 5 the case
work,
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paper discussed
with some ininsights
the
limitations last
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section.
further
work
them, (Grosse,
human Calzavara, Glock, & Sgarbossa, 2017). Among implication of the introduction of Industry 4.0 technologies
work
(Tokar, thatbehaviour
(Grosse,
aspects, 2010). Calzavara,
affect
However,
and decision
Glock,
significantly
it is &worth
making
Sgarbossa,
logistics are
mentioning
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2017). Among
management
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on human
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limitations last section.
technologies
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aspects,
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2010). affect
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and decision making
significantly
and itdecision
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human
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3. OPERATOR 4.0 IN LOGISTICS main areas in which operators will be involved, thanks to the
opportunities offered by IoT and data analysis, which allow
Based on what can be inferred from the analysis of the
full traceability of the material in the process flow. In this
literature, the role of the logistics operator in Industry 4.0 can
case, logistics operators can benefit from real-time
undergo two main evolutions:
information exchange to optimize the supply and transport of
(i) the operator is replaced by the technology for
materials inside the factory. Further, it contributes to the
performing some tasks;
improvement and rearrangement of the production planning
(ii) the operator is supported by new technologies, and
and scheduling if any problem occurs. Technology also
possibly perform more tasks than previously done.
enables new communications mechanisms, which can be
According to previously discussed scientific literature, the used by logistics operators in the coordination of material
hypothesis (i) is more likely to be true for operators and flows. Looking at the whole supply chain, improving the
individual tasks that are strongly related to the use of physical internal logistics performance, exploiting better coordination
force (e.g., material handling) and to continuous and and management of warehouses and transport, can also bring
repetitive activities (e.g., manual packaging, picking benefits to other departments of the enterprise. Logistics
operations) (Grosse et al., 2017). In general, all activities that operator working in the shop floor can support sales
do not bring added value to the process, such as inventory processes, contributing to the improvement of the customer
control and scrap disposal, can be easily automated and service level of the enterprise, with responsive information
assigned to technology rather than operators. However, exchange about material and production management. Such a
scenarios i) and ii) do not represent two mutually exclusive scenario suggests that the work of logistics operators can be
approaches, but industrial logistics systems will evolve affected significantly by technology and new tasks can be
simultaneously towards them. Actually, the replacement of created, enlarging their traditional duties to cross-functional
human operators with the technology in logistics activities and more cognitive activities. Moreover, logistics operators
already happens. A clear example of this is the case of the can benefit from technologies that are complementary to their
increasingly widespread presence of self-driving vehicles that capabilities, thus allowing higher efficiency. For instance, the
are used instead of forklifts and trans pallets to move the use of augmented reality in picking operations can avoid
material inside the warehouses and for transporting products errors and improve the performance, without replacing the
across the production departments and to and from the operator. To realize this perspective, it is worth to mention
storage warehouses (DHL Trend Research, 2014). Inventory that technology affects significantly also the workplace. For
control operations can be nowadays almost entirely instance, logistics operators are increasingly equipped with
automated: in modern warehouses, the Warehouse wearable tools and supported by mobile devices. Human-
Management System (WMS) software allows real-time machine interfaces and communication need to be designed
management of stock, making it possible to know the level of properly, in order to allow the operators to perform their tasks
stock, free and occupied storage areas, the exact position of effectively and efficiently.
each item, and the material departing and arriving, almost in In the following section, some Logistics 4.0 implementations
real time. The use of technologies that allow the automation are shown, and the implications of scenarios (i) and (ii) in a
of the previously listed activities indeed leads to some real context are discussed.
benefits (e.g., productivity, flexibility, traceability) and solve
4. CASE STUDY: ALPHA COMPANY
some of the critical aspects of the relationship between
logistics and human factors highlighted in the previous This research analyses the relationship between the theory
paragraph (e.g., human errors, safety issues). Reducing the and the reality leveraging on an in-depth, single case study.
number of interactions between human and machine allows The single case study research method is particularly
reducing the risks related to them and, therefore, increasing appropriate for exploratory studies discovering relevant
the level of safety in the work environment. In addition, it constructs in areas where theory building is at the formative
contributes to the reduction of the level of uncertainty related stages and for studies where the experiences of participants
to human behaviour by increasing the reliability of operations and context of actions are critical (Bhattacherjee, 2012), such
and the process. It should also be noted that the reduction (if as logistics 4.0. For the developing of the case study, several
not the elimination) of operators repetitive actions with no site inspections and interviews with key figures of the
added value and the transformation of the operators’ duties company (i.e. CEO, HR manager, Operations manager,
from operational to supervision and control tasks should Technological team manager) have been performed. In
make the work less de-personalising by making the operator addition, qualitative evidences form other secondary sources
more autonomous and with a higher possibility of affecting from the company (i.e. presentations, documents, news,
the optimisation of logistics processes. If the operator is not conference extracts) have been analysed in order to
employed in no value-added tasks anymore, the second triangulate the information.
scenario (ii) contributes to filling up the time that previously
the operator used for them, enlarging the variety of tasks to 4.1. Technological innovations introduced
perform, mainly with the support of technology. As a result,
all the tasks concerning decision making or coordination Alpha company is a family firm, active from 1939, located in
activities become the core of the logistics operator work. the north of Italy. The company has two core activities: the
Referring to the previously discussed technological production of “big bags”, that is relatively large, plastic (or
applications of Logistics 4.0, Resource Planning is one of the other similar materials) bags for different industrial
applications, which generates about the 20% of the turnover,
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