Human Factors in Advanced Manufacturing

Large scale shipbuilding projects like the Hunter Class Future Frigate program can benefit greatly from accelerated application of advanced digital and manufacturing technologies in tandem with lean manufacturing and high-performance workplace practices. So too can the supply chains working in support of this national endeavour.

The vision to establish a world class ‘digital shipyard’ is a major driver toward achieving sovereign shipbuilding capability.

Flinders University is proud to be working in collaboration with BAE Systems Maritime Australia and its supply chain to examine the role that human factors and ergonomics (HFE) play in the uptake and diffusion of advanced manufacturing and digital technologies. This page summarises our activities and findings with new content released regularly – look for ‘Just Released’, you may need to scroll down.

A unique transdisciplinary research capability has been assembled at the Flinders at Tonsley campus to drive this work.

With support from the Innovative Manufacturing Cooperative Research Centre (IMCRC) we have embarked on a multi-year program of HFE technology research and trials designed to support the successful and timely uptake of advanced manufacturing and digital technologies in Australian shipbuilding.

BAE Systems Maritime Australia staff are working alongside Flinders researchers on an ambitious research program based in fit-for-purpose collaborative research labs and the Pilot Factory of the Future – Line Zero trial and test facility.

In line with all other forms of manufacturing, Industry 4.0 offers a vision for transformation of the shipbuilding industry though the establishment of ‘Digital Shipyards’ and adoption of a ‘Shipyard 4.0’ agenda.

Research Reports

Quicker off the Blocks: The role of Human factors in the uptake and diffusion of advanced technologies in shipbuilding

Authors: O’Keeffe, V., Moretti, C., Hordacre, A.L., Howard S. & Spoehr, J.

The adoption of Industry 4.0 technology will transform work, shifting toward technologymediated interactions that are less physically demanding, more abstract, loosely coupled and cognitively challenging.

Human Factors and Ergonomics (HFE) provides tools and techniques for analysing and predicting impacts of the transition to Industry 4.0 and designing and integrating solutions to address these impacts.

Summary Report

Full Report

The Digital Shipyard: Opportunities and Challenges

Authors: Spoehr, J., Jang, R., Manning, K., Rajagopalan, A., Moretti, C., Hordacre, AL., Howard, S., Yaron, P & Worrall, L.

Next-generation digital technologies are enabling the creation of ‘Digital Shipyards’, with potential to bring about improvements in productivity, accuracy and repeatability, traceability, visibility and health and safety across the entire shipbuilding value chain.

Digitisation of naval shipbuilding requires structured processes and practices consciously aimed at driving technological improvement and innovation along the value chain. Human Factors and Ergonomics (HFE) provides a framework for achieving this.

Summary Report

Full Report

Naval Shipbuilding and Industry 4.0: Building the Value Chain and Industry Capability

Authors: Worrall, L. & Spoehr, J.

This report explores the present position and future role of digital technologies in the Australian naval shipbuilding industry. Its specific concerns are: why and how, and according to what paths, plans and trajectories the Australian naval shipbuilding industry should adopt and embed digital technologies?

Its goal is industry and enterprise education to help accelerate and drive innovation and capability development along the value chain (Primes, tier 1 and higher tier suppliers, and small and medium-sized enterprises (SMEs)), systematically to address impediments, and identify key success factors and associated measurement and benchmarking tools for use by the industry.

Summary Report

Full Report

Robotics and the Digital Shipyard

Authors: Manning, K., Jang, R., Rajagopalan, A., Spoehr, J., Hordacre, A.L. & Moretti, C.

This report reviews the ‘current state’ of robotics applications in Australian manufacturing to inform considerations about potential applications of the technologies in shipbuilding as part of the digital shipyard ambition. It details a range of use cases and illustrates how the adoption of modern robotics and assistive manufacturing technologies are helping companies to pursue the Industry 4.0 challenge in Australia.

Full Report

From Ship to Shore: Reducing the barriers to collaborative robot uptake in shipbuilding and manufacturing through human factors

Authors: Howard, S., Rajagopalan, A, Manning, K., O’Keeffe, V., Hordacre, A.L. & Spoehr, J.

This report reviews the ‘current state’ of robotics applications in Australian manufacturing to inform considerations about potential applications of the technologies in shipbuilding as part of the digital shipyard ambition. It details a range of use cases and illustrates how the adoption of modern robotics and assistive manufacturing technologies are helping companies to pursue the Industry 4.0 challenge in Australia.

Summary Report

Full Report

Staying on Course: Human factors in navigating digital work orders in harsh environments in shipbuilding

Authors: O’Keeffe, V., Jang, R., Howard, S., Hordacre, A.L. & Spoehr, J.

The potential value of digital technologies has drawn worldwide attention across industries. However, technology implementation is highly complex, and is likely to profoundly change jobs and processes, with significant social implications for people’s interactions and communication.

This report makes eight recocmendations to promote the uptake of digital work order technology in the shipyard and along the manufacturing supply chain.

Summary Report

Full Report

Setting it Straight: Human factors, technology, and pipe alignment in shipbuilding

Authors: O’Keeffe, V., Rajagopalan, A., Manning, K., Howard, S., Hordacre, A-L. & Spoehr, J.

Piping transports energy and wastes throughout ships ensuring safe and efficient operation. Pipework is extensive and complex, and must withstand harsh conditions, meaning all pipe sections must be aligned and welded with high levels of skill to meet stringent quality specifications.

This project compared two pipe alignment tasks: manual and technology-assisted. Results suggest the technology-assisted version has the potential to reduce alignment time, though small sample sizes mean results were inconclusive and further research is warranted. Introducing technology has significantly changes job design, requiring tailored human resources management and change management strategies to sustain benefits.

Full Report

All Hands on Deck: Building Industry 4.0 momentum through University-Industry collaboration

Authors: Spoehr, J., Hordacre, A-L., Moretti, C., O’Keeffe, V., Howard, S., Jang, R., Manning, K., and Trott, R.

All Hands on Deck focuses attention on lessons learnt from a rapidly evolving collaboration between AITI and BAE Systems Australia – Maritime. It examines the contribution played by accelerating the uptake and diffusion of innovative manufacturing technologies in Australian shipbuilding.

Full Report

True North: Key themes for accelerating the uptake and diffusion of Industry 4.0 technology in manufacturing and the supply chain

Authors: O’Keeffe, V., Howard, S., Jang, R., Manning, K., Trott, R., Hordacre, A-L., Spoehr, J., and Moretti, C.

True North summarises key themes that have arisen from the program of research between AITI and BAE that ran from March 2020 to October 2022 aimed at accelerating the uptake and diffusion of Industry 4.0 enabling technologies in shipbuilding and its manufacturing supply chain. This report provides an overview of the project completed and outlines worthwhile areas for future research. The work was funded by BAESA-M in collaboration with the Department of Industry, Science and Resources1 (Innovative Manufacturing CRC).

Full Report

Manufacturing Work by Design: Pillars of successful integration of Industry 4.0 technology into jobs

Authors: Howard, S., O’Keeffe, V., Hordacre, A-L., and Spoehr, J.

This document provides an overarching job design 'framework’ and summary of significant changes to manufacturing work (current and anticipated) resulting from the introduction of emerging, disruptive Industry 4.0 enabling technologies. This focused report complements previous analysis applying a more macro lens (Worrall & Spoehr, 2021).

Full Report

"It's more about the technology and how it works with people, rather than technology for technology's sake" - Sharon Wilson, BAE Systems Maritime Australia

Implementation Guides

These overviews are intended as a technology selection decision support tool, and not a substitute for business procurement processes.

SPOT

Optitrak

Collaborative robot (Cobot)

"It is important to acknowledge just how transformative such a vision is and how challenging it will be to realise.

The motivations and drivers must be powerful and the benefits very large. The ideal of Digital Shipbuilding and importantly, sustainment, is propelled by the prospect of significant improvements in productivity, efficiency, reliability, quality and safety over the lifecycle of vessels.

This is the promise that the Industry 4.0 agenda makes and that HFE can enable."

Professor John Spoehr

Director, The Australian Industrial Transformation Institute

BAE Systems Maritime Australia is our principal industry partner on this project led by Sharon Wilson (Continuous Naval Shipbuilding Strategy Director), Evangelos Lambrinos (Exports and Innovation Manager) and Andrew Sysouphat (Principal Technologist - Hunter Class). Collectively we thank the Board of the IMCRC and David Chuter, CEO for their support for this project. We share their vision for growth of advanced manufacturing in Australia.

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