Simulation Techniques for Ergonomic Performance Evaluation of Manual Workplaces During Preliminary Design Phase

  • Francesco CaputoEmail author
  • Alessandro Greco
  • Marcello Fera
  • Giovanni Caiazzo
  • Stefania Spada
Conference paper
Part of the Advances in Intelligent Systems and Computing book series (AISC, volume 822)


Among the technologies included in Industry 4.0, the fourth industrial revolution, Digital Manufacturing (DM) represents a new approach to evaluate the performance of production processes in a virtual environment.

DM can be seen as the industrial declination of Virtual Reality (VR) that, by using an integrated computer-based system, allows creating simulation, 3D visualization and provides different tools to define the product and the manufacturing process simultaneously.

Virtualization and simulation of production processes generate benefits for companies in terms of time and costs, optimizing the assembly line and providing parameters for studying human-machine interaction.

Regarding this last topic, the aim of this paper is to propose an innovative procedure to support the workplaces design, based on simulation techniques that allow setting a virtual scenario in which a Digital Human Model (DHM) is able to carry on assembly tasks. Data from simulations can be analyzed and used to assess ergonomic indexes in a preventive and proactive approach.

As other automotive manufacturers, Fiat Chrysler Automobiles (FCA) applies EAWS (European Assessment Work Sheet), a first level screening, to assess the ergonomic biomechanical overload of workplaces in the design phase, according to international standards (ISO 11226 and ISO 11228-1, -2, -3).

The ergonomics risk assessment, since the design phase, allows identifying critical issues and to define and put in practice corrective actions in the earlier phase, being more successful and less expensive.

In order to support the procedure proposed in this research, a case study is described, based on the EAWS index evaluation of a workstation in a FCA plant assembly shop.

The simulation has been realized by using PLM software Tecnomatix Process Simulate by Siemens® and the EAWS analysis has been performed by using EAWSdigital by MTM®.

The procedure can be considered innovative to support human-centered design of production process in developing new products.


Digital manufacturing Digital human models Simulation EAWS 


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Copyright information

© Springer Nature Switzerland AG 2019

Authors and Affiliations

  • Francesco Caputo
    • 1
    Email author
  • Alessandro Greco
    • 1
  • Marcello Fera
    • 1
  • Giovanni Caiazzo
    • 2
  • Stefania Spada
    • 2
  1. 1.Department of EngineeringUniversity of Campania Luigi VanvitelliAversaItaly
  2. 2.FCA Italy – EMEA Manufacturing Planning and Control – ErgonomicsTurinItaly

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