Virtual Ergonomics and Time Optimization of a Factory

Abstract

This manuscript focuses on designing the virtual factory which has become a subject of paramount importance to all major manufacturing companies. Such virtual solutions enable to verify all conflict situations before real implementation of factories and to optimize the performance, productivity, timing, costs and ergonomics by using simulation and virtual reality technologies. This model sees a real factory as a combination of various sub-systems and includes them. In manufacturing, it creates a virtual simulation exercise that helps in replicating the real life scenario and helps in designing and implementation. Using ergonomics module, distance traveled from end-to-end departments to complete the entire manufacturing process is calculated. Within the virtual factory, assembly planning and manufacturing planning is demonstrated through real-life worker simulation considering the musculoskeletal disorders (MSD). Awkward working postures and improper workstation design leads to MSD. In this paper, virtual representation of a shop floor activity is done by using a digital modeling tool DELMIA V6. The task is performed by the digital human (manikin) and the ergonomic analysis is carried out virtually for the tasks which includes worst working condition. Simulating the manual tasks in virtual environment, the worker postures have been evaluated using the Rapid Upper Limb Assessment (RULA) Analysis, Lift Lower Analysis and Biomechanics Single Action Analysis which are used to provide the level of risk for the musculoskeletal disorders.