Modified virtual build methodology for computer-aided ergonomics and safety: Research Articles

In the past, computer-based ergonomic analysis has been time-consuming and has required many assumptions when the virtual human motion paths have been programmed. Hence, it appears that many in the human factors and ergonomics profession have not developed much expertise in the Digital Human Modeling area. The Virtual Build method first demonstrated by the Ford Motor Company appears to improve the accuracy and speed of the ergonomic analyses used in design of assembly processes. It allows capture of real-motion and virtual process interaction rather than assuming expected posture and task motion. A variation of the Virtual Build methodology, presented in this article, affords the benefit that both product and process design can be analyzed prior to production and limitations have been overcome. Hardware limitations in the Virtual Build environment previously prevented transfer of the data collection and analysis methods to the real manufacturing environment and limited the ability to validate the predictions from the virtual industrial environment. Preliminary results of the case illustrating the modified Virtual Build research methodology presented in this article appear to be promising in support of computer-aided ergonomics and safety for design of new or existing workstations and consumer products. A mixed-mode virtual-real environment that provides force feedback can be used to supplement the experimental setup and improve fidelity of the interactions in a work design assessment. A summary of the comfort assessment for a product design example that was tested with constrained human motion is outlined in the results section and presented in the context of a summary of key issues in Virtual Interactive Design and Virtual Build Assessments. © 2007 Wiley Periodicals, Inc. Hum Factors Man 17: 413–422, 2007.