Ergonomics Risk Assessment with Digital Human Models in Car Assembly: Simulation versus Real Life

This study investigated how well ergonomics risk assessments on simulations with digital human models (DHM) match real-life assessments obtained on a car assembly line. Two ergonomists evaluated 20 work tasks in real life and as a DHM simulation using a company-specific version of the Automotive Assembly Worksheet (AAWS) for assessing static postures, action forces, manual material handling, and extra strains. Results demonstrate that DHM simulations provide good estimations of the workload in real-life tasks. Additionally, significant correlations were found between AAWS risk assessments and subjectively perceived exertion measured on the Borg scale. Yet, there were also some significant differences in AAWS risk classification and AAWS total scores. DHM simulations appear helpful for reliably detecting static postures and extra strains, whereas action forces are harder to estimate than in real life. It is suggested that comprehensive methods such as AAWS should be incorporated in DHM software for enhancing efficiency and validity of digital ergonomics risk assessment. (C) 2010 Wiley Periodicals, Inc.