Simulations of ergonomic assembly: Ergonomic evaluation using the digital human modelling tool IMMA

Abstract

In regards to the vast amount of work-related injuries in today’s industries, the way to assess and understand ergonomics as we know it, needs to change. Musculoskeletal disorder as result of bad workplace design and ergonomics is one of the leading causes of work-related injuries. This is especially true for the manufacturing sector and the automotive industry. CEVT, among other stakeholders in the industry, is taking initiative to reduce the risk of musculoskeletal disorders and is looking towards simulations and digital tools as a possible solution. On behalf of CEVT, this thesis elucidates the implementation and validation of an automated ergonomic assessment within the digital human modeling software IMMA. The ergonomic evaluation method KIM III was selected as the most appropriate method for implementation regarding CEVT’s needs. The implementation led to an automated ergonomic assessment, providing a PDF report based on the manikins’ posture and additional input data from the user. The implementation was validated against manual KIM III assessments conducted by a CEVT ergonomist and was proven successful. The developed methodology of the thesis has been structured to fulfill the aims of the study and reach an implementation of a full evaluation assessment into the DHM tool IPS IMMA. The focus has been to verify and obtain high validity of the implemented function, which could be achieved after undergoing a vast benchmarking and screening process. The benchmarking and screening process were the result of quantitative and qualitative data analyses and presented the most suitable ergonomic assessment method to be implemented in IPS. The method may be adapted to evaluate the relevance and suitability of ergonomic assessment methods into DHM software. This thesis further addresses the need of future research within the field of virtual reality and motion capture as a way of better understanding the motion and behaviour of assembly workers. Furthermore, future development of digital twins as a way of better understanding the reality of the problem as well as the development of simulation based ergonomic assessment methods is discussed.