Automotive Manufacturing Task Analysis: An Integrated Approach

Automotive manufacturing presents unique challenges for ergonomic analysis. The variety of tasks and frequencies are typically not seen in other industries. Moving these challenges into the realm of digital human modeling poses new challenges and offers the opportunity to create and enhance tools brought over from the traditional reactive approach. Chiang et al. (2006) documented an enhancement to the Siemen's Jack Static Strength Prediction tool. This paper will document further enhancements to the ErgoSolver (formerly known as the Ford Static Strength Prediction Solver). These enhancements include integration of: Jack's Low Back Analysis tool; a modified Rohmert equation for muscular fatigue analysis; strength scaling equations to account for frequency and duration; the initial HUMOSIM Framework (Reed et al., 2006) for standing posture prediction; an automated measuring tool for common human-related measurements; vision windows and head/eye behavior settings; and Excel and PowerPoint reporting capability. Some of the functionality integrated into the ErgoSolver is existing Jack functionality. The goal of integrating these features was to ease the learning curve and increase efficiency for new and experienced users alike. Attempts were made to bring together, organize and present commonly used functionality in a fashion targeted towards the assembly ergonomics professional. Where functionality gaps were found in Jack, new functionality was created and integrated. While some of these features are pure usability features (i.e. shortcut methods for performing routine tasks), others are based on new and emerging research.