Simulation Instead of Trial and Error
An ergonomically designed workstation makes work positions more comfortable for employees—this pays dividends for the company. Volkswagen recognized this effect and the ergonomics engineer working in Volkswagen’s planning division uses DELMIA software from Dassault Systèmes to assist them in executing assigned projects.
The following scenario illustrates what can happen if a company disregards a workstation’s ergonomic aspects: a particular bolt connection was found to be hard to reach and consequently, it was difficult for the assembly worker to tighten the bolt. As the assembly line continues to move along relentlessly at an unchanging speed, the worker was having a hard time keeping up with the pace, making the uncomfortable position more painful after awhile. The result of this could be the entire production line coming to a screeching halt—an outcome no company could afford. In some situations, it might not even be possible to mete delivery times.
Caption: With DELMIA Human, the accessibility of a single component within the engine compartment may be checked. The necessary posture is secured by the RULA analysis.
As an internationally known car manufacturer base din Wolfsburg, Volkswagen has recognized the productivity increasing effects on an optimized workstation and has appointed an engineer to improve the interface between man and machine. Since the beginning of the year, Maileen Zander has been serving as a consultant for Volkswagen’s various vehicle projects in all matters pertaining to workstation ergonomics.
“The many inquiries coming in from all vehicle classes show that workstation ergonomics is a hot topic with a lot of room left for development,” said Zander.
At the Juncture Between Development, Production, and Medicine
“On the one hand. We have more and more employees complaining about physical problems, and on the other, divisions see the potential of manufacturing better quality products in a faster, more cost-effective manner using optimized work procedures,” said Zander.
This issue also applies to physically disabled employees. Their respective workstations need to be customized to a given employee’s physical capabilities, or they need to be configured in such a manner that they will also accommodate disabled employees.
Simulate First, Then Change
As soon as Zander received a department’s request to optimize a workstation, she analyzes the existing work environment using pre-defined criteria. Given that employees’ task procedures are often complex, she uses DELMIA Human software, which enables he to create human CAD models called manikins.
“DELMIA Human gives me the capability to first simulate work environments on the computer and to check their suitability before we implement them in real life,” she said. The alternative would be to first change the work environment and then check whether the results actually reflect the desired improvements.
DELMIA – Complex but Logical
“DELMIA Human is a complex, highly sophisticated system; however, the program is set up in a very logical manner. I was able to master it fairly quickly and then turn it into a very productive tool,” explains Zander. After she became familiar with the software, the required CAD data, had to be stored in DELMIA. Now, Zander is able to depict an entire workstation environment, as well as add and move human models. She can assign the manikins various parameters, such as sex and population groups. In addition, she can also modify different anthropometric variables, like height and weight.
System Automatically Displays Possible Postures
Of the 65 moveable body parts, 49 can be highlighted with individual colors. Certain body parts and areas like the spine, chest area, lumber region, or pelvis can be blocked or activated in the simulation. Objects can be added to the manikin, such as a hardhat that automatically moves with every motion. The field of vision also adjusts dynamically to the manikin’s movements. “Since the system simulates many standard positions and one can also expand the body posture library, so one is spared form having to manually model every new position,” said Zander. If actually conditions require a deviation from the standard positions, they can be modified accordingly. The only limitation is what is anatomically possible, i.e. DELMIA Human cannot simulate motions on the manikins that are impossible in real life. “For example, you can only rotate an arm backward to a certain point,” explained Zander.
The manikin cannot only move autonomously, it can also walk on reference surfaces. In addition, DELMIA Human contains functions for climbing stairs and ladders, whereby the body automatically moves in synch with the limbs used. The human models can grasp objects within their reach as well. What’s more, it is possible to determine the projected effort required for a certain activity when an individual is in a particular body position. “DELMIA Human can show me, for example, what the maximum weight of an object can be for a person to be able to carry it from A to B without injury,” explained Zander.
Scientific Analysis Methods
Not only can body postures and movements be depicted, but ergonomic factors can be analyzed, too. The system incorporates the RULA (Rapid Upper Limb Assessment) analysis method, developed by the University of Cambridge, which indicates what strain an assembled position can place on the body. The analysis uses a point rating process and RYG (red/yellow/grebe traffic light) visualization. Other scientifically recognized analysis methods like those developed by Snook and Ciriello, as well as the National Institute for Occupational Safety and Health are also integrated within the software.
“DELMIA Human is an absolutely essential tool for my work,” said Zander, emphasizing the software’s important role. “Without the true-to-life simulation, we would be able to verify our findings in the early planning phase.”
Results are Positive
Zander is convinced that Volkswagen will continue to give the topic of workstation ergonomics a high priority in the future. “Since I started here, we have received many requests from various divisions. It shows that our internal customers have recognized the software’s potential.” The results Zander has achieved so far are most positive and have made the leap from computer simulation, such as where the pre-assembly of the doors for the Golf’s successor model were ergonomically optimized.
Virtools Releases Wii Solutions 1.1
Dassault Systèmes has announced that it has released its Virtools package of prototyping and full game production tools for the Nintendo Wii, giving developers for the console access to the Behavior Engine and the VSL compilation, as well as new Wii dedicated functionalities.
Dassault says the Wii solutions are "add-on libraries of building blocks specifically dedicated to Wii game prototyping and game development. Game developers will be able to test on the console anytime during the development, using the power of Virtools 4 and its 500 building Blocks and accessing the Wii Remote information from a Virtools application running directly on the PC."
The company says its Wii-dedicated package will aid in the prototyping and production of not just retail Wii games, but also those for its forthcoming download service, WiiWare.
It also notes that developers will be able to prototype with the WiiMote and tweak the gameplay directly on PC, as well as test output on the console at any point during game development.
"Virtools Wii solutions give the developers the opportunity to validate game design decisions much faster and focus on gameplay production and optimization, creating games with outstanding graphics and cutting edge interactivity," said Dassault.
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