The Client
Ford's Pilot Plant at Aveley, UK, have invested in an Ergolab, a final assembly manufacturing facility that uses virtual reality and motion capture technology to simulate assembly operations. The Lab seeks to reduce ergonomic injuries resulting from product and process design, assembly techniques and technologies.
The Challenge
The Ford Ergonomic Process is about fitting the work to the operator. Previously, ergonomic assessments were carried out during the later stages of a vehicle launch, and concentrated on containment solutions rather than designing out risks. By making assessments before launch and identifying ergonomic risks earlier, Ford aimed to facilitate design-led solutions. Costly last-minute changes, such as tooling or workstation alterations experienced in previous programmes, would therefore be avoided.
The Solution
Simulation Solutions supplied "JACK" from EDS, a highly advanced 3D simulation and ergonomic assessment tool, which enabled Ford to develop parts and assembly processes using digital data and prototype parts. With JACK, the operator is connected to a digitally synthesised human manikin and placed into a digitally created working environment. The ErgoLab takes digital data from product development, digital factory surveys and suppliers' information - e.g. racking, line side stock containers, trolleys etc. - and combines them to show a realistic working environment. Using advanced motion capture technology, they can capture the exact movements the operator makes while assembling a part. These movements are captured and stored in real time within JACK, and can be replayed and analysed for further ergonomic assessment.
The Benefits
By carrying out assessment techniques within JACK, Ford have been able to extend the scope of their assessment to include non-assembly areas such as line side racking and decanted market places.
Development costs and time are reduced while performance, fit and safety are enhanced.
Detailed evidence is obtained and fully documented back-up provided, enhancing the efficiency of ergonomic developments.
Ergonomic solutions are much more robust and effective, and long lead times in prototype development are avoided.
product overview
