Parameterized design optimization framework for worker-friendly workplaces in modular construction

Addressing ergonomic risk factors in modular construction is critical to enhancing the productivity of production lines and reducing the societal cost burden for worker recovery. Ergonomics-driven workplace design is thus essential to not only proactively reducing risks through design changes but also accommodating medical restrictions for workers returning to work after an injury or illness. However, efforts to realize this two-fold approach are confounded by the lack of a sound approach to identifying the root causes of ergonomic posture risks among various workplace design parameters or an optimal workplace design for multiple tasks. To address this limitation, this paper proposes a parameterized workplace design optimization framework that consists of four core components: workplace design initiation, interactive worker-workplace simulation, development of predictive surrogate models, and workplace optimization. The framework is demonstrated through a case study designing a drywall preparation workplace in a real modular construction plant. The results show that the framework enables the design of the optimal workplace (i.e., the one with minimal ergonomic risk) and provides a guide for devising practical action plans for safety improvement.