The study aimed at analyzing the relationship between assembly ergonomics, assemblability ("ease of assembly"), and product quality and at quantifying these relationships in economic terms. This was in order to better to support the development of more ergonomic product and assembly solutions, particularly at early stages of the car development process. The assembly of 24,443 cars was studied for 8 weeks in an assembly plant and for another 16 weeks as factory-complete vehicles. The results show increased risks for quality errors of 3.0 and 3.7 times and total action costs that were 8.7 times and 8.2 times higher for high and medium physical load assemblies compared to low physical load assemblies for 55 tasks assessed. C 2009 Wiley Periodicals, Inc.

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Simulation can support the design of an ergonomic workplace by enabling early assessment of ergonomic conditions in a virtual environment. An important feature is the possibility to study alternative solutions or the effect of improvements from an ergonomics perspective. To be able to conduct an efficient and reliable evaluation in a virtual environment, an objective analysis method is essential. Such an analysis method should be integrated in the simulation software, and support a company's everyday ergonomics work process. In order to gain from existing ergonomics knowledge within a company, the possibility to implement such wisdom in the current simulation software becomes important.This paper presents an implementation work done with the purpose of integrating an established ergonomics work process into a virtual environment. It describes the benefits of an ergonomics work process where simulation and evaluation at early stages of a design process are key factors. The paper will also describe the integration process, i.e., the technical issues as well as the change in work methods.Keywords: simulation; ergonomics; workplace design.Reference to this paper should be made as follows: Bäckstrand, G., Högberg, D., De Vin, L.J., Case, K. and Piamonte, P. (2007) ; and MSc (1995) and PhD (2000) degrees in Industrial Ergonomics from Luleå University of Technology, Sweden. He manages different projects in the areas of product and production ergonomics for different Volvo companies and their clients. His group is also involved in several national (Swedish) and EU-sponsored projects in the same areas.

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To build software which, at the press of a button, can tell you what cognition related hazards there are within an environment or a task, is probably well into the future if it is possible at all. However, incorporating existing tools such as task analysis tools, interface design guidelines and information about general cognitive limitations in humans, could allow for greater evaluative options for cognitive ergonomics. The paper discusses previous approaches to the subject and suggests adding design and evaluative guiding in Digital Human Modelling that will help a user with little or no knowledge of cognitive science to design and evaluate a human-product interaction scenario.