A software‐based method for ergonomic posture assessment in automotive preproduction planning: Concordance and difference in using software and personal observation for assessments

Abstract

This article describes the pilot study for testing a system for ergonomic posture assessment.1 The software‐based approach for ergonomic assessment is based on motion capturing work tasks using realistic mock‐ups of the assembly environment. The approach for ergonomic assessment reduces the expenditure of time for evaluation. This may lead to considerable ergonomic aspects during the early stages of production planning. A comparative test between human observers and the software system was carried out. The test of the system focuses on correct recognition of postures from the motion data and compares the computer‐based evaluation with the results of a manual analysis carried out by a human observer. The tests indicate sufficient results for the automated assessment, especially for the arm and leg postures. But there is still some potential for further improvement of the recognition accuracy of the back postures. © 2011 Wiley Periodicals, Inc.

Application Of Motion Capture Systems In Ergonomic Analysis

“…Usually, the motion capture setup time is about 20 min, but still this method is considered more efficient than any other tool or technology (Klippert, Gudehus, Zick, 2012). However, there is no a unique opinion about the motion capture systems and digital human models.…”

“…Designing a vehicle for production requires conditions and capabilities to ensure the large volume of production, recruiting the required number of employees (Faraway & Reed, 2007). Though the automotive industry is rather advanced, variety of parts and details used for the vehicle production are made and produced manually, which significantly affect the ergonomics (Klippert, Gudehus, Zick, 2012). A large number of studies have shown that proper ergonomics can not only improve the workers' health but also have a positive economic impact on the company (Fritzsche, 2010).…”

“…A study conducted in 1995 revealed that the rate of quality 109/148 deficiencies identified in the car assembly process was three times higher in work tasks and procedures were ergonomic problems were obvious (Eklund, 1995). It is therefore essential to implement the ergonomic workplace design when starting the layout and facility planning for the designed production, in order to reduce the extra costs in the future production process (Klippert, Gudehus, Zick, 2012). It is highly suggestive to consider the ergonomics in early stages of the product development process, analyzing the interaction of a person with the product.…”

“…Nowadays, the process of product realization is mainly constrained by high cost and time restrictions where the major costs are based on an inefficient physical work (Högberg, Bäckstrand, Lämkull, Hanson et al, 2008). For the recent decades the computer based visualization or simulation methods are widely used for early evaluation, and verification of critical design parameters specific for the ergonomics (Chaffin, 2005;Klippert, Gudehus, Zick, 2012). For this purpose, digital human models (DHM) are used by design engineers in early stages of product development processes.…”

“…This touches also the question of physical ergonomics for assembly workers. Research evidence indicates that DHMs can reduce the engineering costs and have to be implemented in the early development process (Chaffin, 2005;Klippert, Gudehus, Zick, 2012). By reducing the production time and costs, these technologies increase the profitability, as well as the product quality (Högberg, Bäckstrand, Lämkull, Hanson et al, 2008).…”