Digital Human Modeling Simulation Results and Their Outcomes in Reality: A Comparative Study within Manual Assembly of Automobiles

The objective of this study was to examine to what extent ergonomics simulations of manual assembly tasks correctly predict the real outcomes in automotive assembly plants, and if recommended measures originating from ergonomics simulations are considered. 155 ergonomics simulation cases done by nine simulation engineers at Volvo Car Corporation in Gothenburg were used in the study. The evaluations of the ergonomics conditions in reality of the cases were done by six professional ergonomists working in the company. The results show that digital human modelling tools are useful for providing designs for standing and unconstrained working postures as well as for the design of various auxiliary devices and their needed space for movements. The study also identifies areas that require additional development in order to improve the digital human modelling tools’ ability to correctly predict a work task's real outcome. Moreover, a better feedback of product and process changes, and a more careful order description to the simulation engineers, would improve simulation results in current and future projects.