Applications and benefits of digital human models to improve the design of workcells in car’s manufacturing plants according to international standards

During last years, the car’s manufacturing process has deeply changed because of several factors affected the automotive global scenario. As a consequence, design methodologies of the plant’s workcells have changed. In particular, ergonomics for manufacturing system has become a key factor to improve product’s quality, safety and work organization. In this paper, the authors show the approach used in Fiat Group Automobiles (FGA) based on simulation tools to analyse ergonomic aspects of work-cells already in design phase. Simulation tools allow a deep postural analysis that is one of the main criticism in the design phase. The principles of Digital Human Modeling have been used to develop an easy internal virtual manikin, the Human Model. The tool, based on ISO standards and on a worldwide anthropometric database, allows designers to simulate the most probable postures engaged by operator during work tasks as well as to validate improvements and corrective actions.