A Digital Twin Framework for Real-Time Analysis and Feedback of Repetitive Work in the Manual Material Handling Industry

Manufacturing Operator Ergonomics: A Conceptual Digital Twin Approach to Detect Biomechanical Fatigue

“…The "Visibility" element of operator DT development can be accomplished via advanced tools and dedicated software development kit dashboards with the ability to be customized on-demand. The current framework withholds the capability to integrate multiple software [11] to represent the operator's futuristic avatar with a real-time diagnosis of lifting motion and advanced training of the new generation workforce. The discussed framework is a conceptual model with a high abstraction level, considering minimum details of the system about the development of a true DT.…”

“…However, the results show that there is still a need for research to make workers safe on the job. As human involvement plays an essential role in the productivity of the system, risks related to MMH tasks associated with the nature of the load, type of task, work environment & the operator [25] allow the use of technology to analyze the ergonomics of the work environment to reduce worker fatigue [11]. Multiple tools have been introduced to measure fatigue in the workforce.…”

“…Lack of including the object's weight, a significant component of MMH tasks, as a decision variable is considered another limitation of currently used methods. In recent times, virtual human factor (VHF) tools such as virtual reality [36], digital human models [11], and discrete event simulation allow users to perform an ergonomic assessment of systems not yet constructed [37]. A novel tool created by Greig et al [38] used methods like biomechanical regression modeling and Methods-Time Measurement to predict worker demand and element-time, along with assisting the user inline layout and task balancing.…”

“…Prior research by [10] [11] provides a framework to conceptualize the DT of an MMH operator. The framework (Figure 1) includes the following three modules: 1) Data Collection Module, 2) Operator Analysis & Feedback Module, 3) Digital Twin Module.…”

“…The data collected are then stored in a database for further analysis. The Operator Analysis & Feedback Module conceptualizes data analysis, optimization, and forecasting based on joint movements, type of motion [11], and biometric factors [12]. The Digital Twin Module presents the visualization of analyzed operator statistics in a simulated environment as feedback to the operator and stores the operator activity metrics for further research and development.…”