On the use of Virtual Reality for a human-centered workplace design

In the Industry 4.0 and digital revolution era, the world of manufacturing industry is experiencing an innovative reconfiguration of design tools and methodologies, with a different approach to the production processes organization. The design philosophy is changing, integrating to engineering contribution interpretative aspects (design thinking), executive practices (design doing) and cognitive aspects (design cultures). The design becomes human-centered. The new Virtual Reality technologies allow to validate performances of designed products and production processes by means of virtual prototypes in a virtual simulated environment. This approach generates several benefits to the companies, in terms of costs and time, and allows optimizing the assembly line design and related workplaces, by improving workers' benefits too. This paper proposes an innovative method to validate the design of workplaces on automotive assembly lines in a virtual environment, based on ergonomic approach, according to ERGO - Uas system, applied by FCA (Fiat Chrysler Automobiles) groups, that integrates UAS method for measurement and EAWS method for biomechanical effort evaluation. Creating 3D virtual scenarios allows to carry on assembly tasks by virtual manikins in order to be evaluated from different points of view. In particular, data coming from the simulation can be used to assess several ergonomic indexes, improving safety, quality and design. The analysis is supported by the use of a motion capture system, developed by the University of Campania and composed of wearable inertial sensors, that estimates the attitude of fundamental human segments, using sensor fusion algorithms based on Kalman filtering. In this way, it is possible to make a further design validation, assessing the EAWS index basing on posture angles trends evaluated. This method can represent an innovation for human-centered design of workplace in developing new products, reducing costs and improving job quality