A framework for integrated design of human–robot collaborative assembly workstations

Abstract

Collaborative robotics is increasingly considered in manufacturing to improve efficiency while reducing operators physical and cognitive workloads. However, the lack of comprehensive methodologies has limited the consistent implementation of human–robot collaborative workstations across industries. Existing approaches are often fragmented, require robotics expertise, and pose challenges for non-experts, leading to suboptimal station designs and inefficient task allocation. This study presents a structured design framework to transition traditional assembly processes into collaborative ones. The framework provides a practical, scalable solution for optimizing collaborative workstations, balancing performance, ergonomics, and industrial applicability. It starts from the analysis of the assembly tasks, followed by classification and allocation between human operators and robots, and concludes with virtual prototyping and performance optimization through simulation using a commercial tool. The adopted methodology integrates task analysis, ergonomic assessment, and workspace design to ensure accessible and efficient implementation. Validated through two industrial case studies involving a gear pump and a worm gearbox, the approach demonstrated significant reductions in cycle time and notable improvements in the ergonomic working conditions. Additionally, physical prototyping and testing conducted within a research collaborative cell further confirmed the achieved results. • A design framework for designing human–robot collaborative assembly workstations is proposed. • The method integrates digital tools for task analysis, ergonomic assessment and workspace design. • A virtual prototype of the cell is used to assess assembly performance and ergonomic conditions. • Two industrial case studies validate the approach in real production contexts.