scholarly journals Optimizing Ergonomics and Productivity by Connecting Digital Human Modeling and Production Flow Simulation Software

2020 ◽  
Author(s):  
Aitor Iriondo Pascual ◽  
Dan Högberg ◽  
Anna Syberfeldt ◽  
Erik Brolin ◽  
Lars Hanson
Keyword(s):  
Human Factors ◽  
Production Line ◽  
Flow Simulation ◽  
Simulation Software ◽  
Production Data ◽  
Production Flow ◽  
Digital Human Modeling ◽  
Human Modeling ◽  
Simulation Results ◽  
Digital Human

Simulation software is used in the production development process to simulate production and predict behaviors, calculate times, and plan production in advance. Digital human modeling (DHM) software is used to simulate humans working in production and assess whether workstation designs offer appropriate ergonomic conditions for the workers. However, these human simulations are usually carried out by human factors engineers or ergonomists, whereas the production simulations are carried out by production engineers. Lack of integration of these two simulations can lead to suboptimal solutions when the factory is not optimized to improve both productivity and ergonomics. To tackle this problem, a platform has been developed that connects production flow simulation software data and DHM software data and integrates them in a generic software for data treatment and visualization. Production flow simulation software data and DHM software data are organized in a hierarchical structure that allows synchronization between the production data and the ergonomic data on the target simulation software. The platform is generic and can be connected to any production flow simulation software and any DHM software by creating specific links for each software. The platform requires only the models of the production line, workstations, and tasks in order to perform the simulations in the target simulation software and collect the simulation results to present the results to the user of the platform.

Exploring the Design Space Using a Surrogate Model Approach With Digital Human Modeling Simulations

2018 ◽  
Author(s):  
Salman Ahmed ◽  
Mihir Sunil Gawand ◽  
Lukman Irshad ◽  
H. Onan Demirel
Keyword(s):  
Human Factors ◽  
Surrogate Model ◽  
Human Performance ◽  
Design Method ◽  
Human Subjects ◽  
Design Stage ◽  
Digital Human Modeling ◽  
Design Variables ◽  
Human Modeling ◽  
Digital Human

Computational human factors tools are often not fully-integrated during the early phases of product design. Often, conventional ergonomic practices require physical prototypes and human subjects which are costly in terms of finances and time. Ergonomics evaluations executed on physical prototypes has the limitations of increasing the overall rework as more iterations are required to incorporate design changes related to human factors that are found later in the design stage, which affects the overall cost of product development. This paper proposes a design methodology based on Digital Human Modeling (DHM) approach to inform designers about the ergonomics adequacies of products during early stages of design process. This proactive ergonomics approach has the potential to allow designers to identify significant design variables that affect the human performance before full-scale prototypes are built. The design method utilizes a surrogate model that represents human product interaction. Optimizing the surrogate model provides design concepts to optimize human performance. The efficacy of the proposed design method is demonstrated by a cockpit design study.

scholarly journals USULAN DESAIN CHECKING FIXTURE DENGAN METODE DESIGN FOR MANUFACTURING AND ASSEMBLY YANG ERGONOMIS

2020 ◽  
Vol 4 (2) ◽  
pp. 269
Author(s):  
Hanna Setyoningsih ◽  
Asep Endih Nurhidayat ◽  
Atfal Murodif
Keyword(s):  
Modeling And Simulation ◽  
Design For Manufacturing ◽  
Simulation Software ◽  
Manufacturing Companies ◽  
Digital Human Modeling ◽  
Assembly Method ◽  
Make To Order ◽  
Human Modeling ◽  
Digital Human ◽  
Human Modeling And Simulation

A work tool that don’t have ergonomic aspects can cause excessive fatigue to injury when used. As a result of excessive fatigue on workers can reduce the level of productivity and harm the company. PT. X is a manufacturing companies with make to order type of production. PT. X received a complaint from a customer who suffered a musculoskeletal muscle injury while using a checking fixture work tool. Checking fixture is a supporting component in the process of making a product that has a great influence on the quality of the product that will be optimized for its function and geometry. The study was conducted to find a checking fixture design that suits the customer's wishes. Ergonomic aspect analysis will be carried out to determine the dimensions of the dimensions in the process of making the design of the checking fixture by considering several things including the distance of the hand's reach to the locator pin, the height of the checking fixture, the standing position and the position of the grip checking fixture. Ergonomics analysis will be conducted using digital human modeling and simulation software. The design for manufacturing and assembly method is used to determine the costs required to make a checking fixture. Based on the analysis of the design, the proposal shows that there is an improvement in the work posture, which is indicated by a decrease in the PEI value from 2.73 to 1.82 so that the number of production has increased to 93 units. Based on the analysis of design for manufacturing and assembly the cost of making the checking fixture is Rp. 5,145,115,000/item. Keywords : Antropometri; Nordic Body Map; Posture Evaluation Index.ABSTRAKSebuah alat kerja yang tidak memenuhi aspek ergonomis dapat menyebabkan letih berlebih hingga cidera ketika digunakan. Akibat dari letih berlebih pada pekerja dapat menurunkan tingkat produktivitas dan merugikan perusahaan. PT. X adalah perusahaaan manufaktur dengan tipe produksi make to order. PT. X mendapat keluhan dari pelanggan yang mengalami cidera otot muskuloskeletal ketika menggunakan alat kerja checking fixture. Checking fixture merupakan satu komponen pendukung dalam proses pembuatan produk yang sangat berpengaruh besar terhadap kualitas produk yang akan dioptimalkan fungsi maupun geometrinya. Penelitian dilakukan untuk menemukan desain checking fixture yang sesuai dengan keinginan pelanggan. Analisis aspek ergonomis akan dilakukan untuk menentukan standar dimensi dalam proses pembuatan desain checking fixture dengan mempertimbangkan beberapa hal diantaranya jarak jangkauan tangan ke locator pin, tinggi checking fixture, posisi berdiri dan posisi genggaman checking fixture. Analisis ergonomi akan dilakukan menggunakan software digital human modeling and simulation. Metode design for manufacturing and assembly digunakan untuk mengetahui biaya yang diperlukan untuk membuat checking fixture. Berdasarkan analisis desain usulan menunjukkan bahwa terjadi perbaikan postur kerja yang ditunjukkan dengan menurunnya nilai PEI dari 2,73 menjadi 1,82 sehingga jumlah produksi mengalami peningkatan menjadi 93 unit. Berdasarkan analisis design for manufacturing and assembly biaya pembuatan checking fixture adalah Rp. 5.145.115.000 per unit. A work tool that don’t have ergonomic aspects can cause excessive fatigue to injury when used. As a result of excessive fatigue on workers can reduce the level of productivity and harm the company. PT. X is a manufacturing companies with make to order type of production. PT. X received a complaint from a customer who suffered a musculoskeletal muscle injury while using a checking fixture work tool. Checking fixture is a supporting component in the process of making a product that has a great influence on the quality of the product that will be optimized for its function and geometry. The study was conducted to find a checking fixture design that suits the customer's wishes. Ergonomic aspect analysis will be carried out to determine the dimensions of the dimensions in the process of making the design of the checking fixture by considering several things including the distance of the hand's reach to the locator pin, the height of the checking fixture, the standing position and the position of the grip checking fixture. Ergonomics analysis will be conducted using digital human modeling and simulation software. The design for manufacturing and assembly method is used to determine the costs required to make a checking fixture. Based on the analysis of the design, the proposal shows that there is an improvement in the work posture, which is indicated by a decrease in the PEI value from 2.73 to 1.82 so that the number of production has increased to 93 units. Based on the analysis of design for manufacturing and assembly the cost of making the checking fixture is Rp. 5,145,115,000/item.

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