Workplace design ergonomic validation based on multiple human factors assessment methods and simulation

According to the international literature postures, exerted forces, manual handling and repetitive actions with upper limbs must be considered in order to estimate the workers’ exposure to biomechanical overload risk, but also a preventive ergonomic approach in the design phase is possible. Within the Industry 4.0, the digitalisation of manufacturing processes generate benefits in terms of production costs and time. Regarding the ergonomics, it is possible to set up a predictive model for the evaluation of biomechanical overload risk. This paper proposes an appraisal of a workplace design and ergonomics validation procedure based on simulation: data from assembly tasks simulation of Digital Human Models (DHM) can be used to assess the ergonomic indexes (OWAS, NIOSH, OCRA, EAWS, etc.). So, it is possible to preventively solve ergonomic risks during the design phase. A test case, regarding a real workplace of an assembly line of an important automotive Company, is also presented.