Digital manufacturing in fiat group automobiles: virtual simulations for preliminary ergonomics optimization of workcells in the design phase of a new car model

New standards on work organization in the automotive industry, require a new concept of design methods: the human centred process. In Fiat Group Automobiles (FGA) the “Digital Manufacturing” (DM) project has started with the goal to create simulation tools and methods to improve the design of new cars’manufacturing processes giving a special attention to manual operations. The DM approach is based on a detailed “virtual plant” where virtual mannequins interact with digital models of car’s components, equipment, containers, etc. in order to simulate and improve working conditions with many benefits on ergonomics, safety, final product quality, work organization and general production costs. The key factor for this approach is that with DM methodologies, designers and engineers have, already in the design phase of a new car’s manufacturing process, a preliminary estimation of the numerical indices used in the plants to check if workcells are compliant to international standards and regional safety laws. In this way the most important ergonomic indices (like Niosh, Snook & Ciriello, EAWS, etc.) become a “design tool” that allow to change/improve project solutions (designing easy and comfortable work tasks, equipment, tools, etc.) and to distribute the work load in an optimal way between workers.