Integrating ergonomics Integrating ergonomics into Ford’s Virtual into Ford’s Virtual Manufacturing Process Manufacturing Process Dan Drouin, Patty Edison and A. Stephens Dan Drouin, Patty Edison and A. Stephens Ford Motor Company Ford Motor Company
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Integrating ergonomics Integrating ergonomics into Ford’s Virtual into Ford’s Virtual Manufacturing ProcessManufacturing Process
Dan Drouin, Patty Edison and A. StephensDan Drouin, Patty Edison and A. StephensFord Motor CompanyFord Motor Company
Vision: Seamless information, Collocated teams, Expert resourcesVision: Seamless information, Collocated teams, Expert resources
Virtual Center
IDEAS
WITNESS SIMUL8
DIGITALBUCK
POWERTOOLLIBRARY
PDLA
LASER SCAN
eMS
ROBCAD
Tooling Supplier
ManufacturingEngineer
Product Supplier
SimulationEngineer
Product Engineer
Program Module Team
Plant Vehicle Team
Plant Engineer
Ergonomics
JACK
Ergo VB Process Flow.igx
ProgramSupported by
VME
Product Data
Entered into eM-Planner
Process Data
Entered into eM-Planner
Resource Data
Entered into eM-Planner
Ergo Reviewof PPR
Required
Complete "Quick-FED"
Checklist
Attach to Shared Drive and Work Cell in eM-Planner
Passes all Ergo Filters
Update Status to Yellow on VME
deliverables matrix
Deep Dive Ergo
Analysis Required
No
DetermineAnalysis Tool
Analysis Acceptable
Complete FEDS Analysis
Complete Jack/WCHS
Analysis
Yes
Initiate/Update AIMS (Severity 4).
Start
End
Yes
No
Update status to Red on VB deliverable
matrix
Store analysis results in eM-
Planner
Update status to Green on
VME deliverables
matrix.
Close AIMS(If Applicable)
Store analysis results in eM-
Planner
Yes
Product/Process Resource changed
to resolve issue.
eM-Planner and VME Matrix Updated: parts, processes, resources
Perform follow-up Ergo
Analysis to Verify
Resolution
No
End
No
End
Yes
No
End
Yes
Virtual Series Event Ergo Process
Ergo Virtual Build Process Flow
VME Deliverable Matrix : VME Deliverable Matrix : A plan for every partA plan for every part
Ergo VB Process Flow.igx
Return to Main
Return to VME Contact
VME Deliv erable Matrix - Tracks Status of Inputs and Deliv erables of Virtual Build.
Virtual Manuf acturing and Ergonomic Engineers update Matrix.
Stored in Central Location (eRoom or Shared Driv e).
eMeM--Engineer Engineer –– Hand access and ReachHand access and Reach
Ergo VB Process Flow.igx
Return to Matrix
Documenting the Documenting the GreensGreens
Ergo VB Process Flow.igx
Return to Main
Deep Dive Analysis Required Deep Dive Analysis Required –– Matrix updated.Matrix updated.
Ergo VB Process Flow.igx
Workstation status is Yellow pending Deep Dive Analysis
THE FEDS:THE FEDS:Ford Ergonomic Decision SystemFord Ergonomic Decision System
FEDS: “GardenFEDS: “Garden--Path”Path”
Analysis ToolsAnalysis Tools
Liberty Mutual Tables, Snook & Cirello, 1991.Liberty Mutual Tables, Snook & Cirello, 1991.Metabolic Equations (Garg Equations)Metabolic Equations (Garg Equations)Epidemiological TablesEpidemiological TablesRapid Upper Limb Assessment (RULA)Rapid Upper Limb Assessment (RULA)University of Michigan 3DSSP, 2000.University of Michigan 3DSSP, 2000.Eastman Kodak/H. Henry Dreyfuss Associates HumanScale DataEastman Kodak/H. Henry Dreyfuss Associates HumanScale DataNIOSH Lifting Equation, Waters et al., 1993.NIOSH Lifting Equation, Waters et al., 1993.Manual Material Handling: Mital TablesManual Material Handling: Mital TablesAmerican Conference for Governmental Industrial Hygenists (ACGIHAmerican Conference for Governmental Industrial Hygenists (ACGIH) Threshold Limit ) Threshold Limit Values (TLV)Values (TLV)Electrical Connection ToolElectrical Connection ToolDynamic Hand Impact Tool (DIMT)Dynamic Hand Impact Tool (DIMT)Rhomert Rest AllowancesRhomert Rest AllowancesAnthropometric DataAnthropometric DataElectromyographyElectromyographyJack 4.0 / Human SimulationJack 4.0 / Human Simulation
FEDS: “UserFEDS: “User--friendly” Softwarefriendly” Software
Jack Analysis Jack Analysis –– Deep DiveDeep Dive
Ergo VB Process Flow.igx
Return to Main
Hand clearance and reach to
install fuel line to fuel rail
pierce point.
Motion Capture for Motion Capture for Advanced StudiesAdvanced Studies
Potential Potential issues undergo issues undergo a deep dive a deep dive ergonomic ergonomic analysis.analysis.Engineers and Engineers and Operator can Operator can be participantsbe participants
Optical Motion Optical Motion Capture EquipmentCapture Equipment
Benefits:Benefits:No interference No interference from magnetic from magnetic fields and objectsfields and objectsAllows for real Allows for real parts to be used parts to be used a propsa propsIncreased Increased freedom of freedom of motionmotion
Risk Assessment Risk Assessment Scorecard Scorecard
RED: Strength: Ergonomic analysis shows job is unacceptable to 75% of female population.
Reach: Ergonomic analysis shows reach is unacceptable for 5th
percentile female.
Access: Ergonomic analysis shows access unacceptable for 95th
percentile male.
GREEN: Ergonomic analysis shows job is acceptable to 75% of female population.
Reach: Ergonomic analysis shows reach is acceptable for 5th
percentile female.
Access: Ergonomic analysis shows access acceptable for 95th
percentile male.
VME Deliverable Matrix VME Deliverable Matrix –– Updated after Deep DiveUpdated after Deep DiveErgo VB Process Flow.igx
Return to Main
VME Deliverable Matrix Ergonomic Flags
Return to Ergonomic Triggers
eM-Engineer Review Example
Workstation status is Green based on Deep Dive Analysis
File Link in eMFile Link in eM--PlannerPlannerErgo VB Process Flow.igx
Screen Capture of Attachment Tab in eM-PlannerReturn to Main
Ergo VB Process Flow.igx
Return to Main
Issue Tracking in Central LocationIssue Tracking in Central LocationAIMSAIMS
Ergo Health ChartErgo Health Chart
Uxxx Body Area Part Ergo Reviews
050
100150200250300350
SA PH PA PR CP
Program Milestone
# o
f Pa
rts Reviewed by Ergo
Available in eMS
Total Expected
ERGO Standards for Assembly Feasibility Studies
Please use the following human standards for virtual builds and ergonomics studies
Use 95 % male for all hand clearance issues.- Add 3.0mm clearance envelope to account for gloves/clothing
Use 5% female for all reach issues (standing and sitting).
Use 95% male for all happy seat ingress/egress/head clearance
Flag all standing overhead head work above 62 inches. Add plane to eM-Human.
Flag all sitting overhead work 26 inches. Add plane to eM-Human
Maximum forward reach is determined by maximum reach zone
Preferred 0-18”
Less-Preferred 18-
32”
Not Recommended
Overhead
Work zone
Preferred Work zone
71.5”76”
Less-Preferred
Less-Preferred
62”
49”
34”
25”
Not Recommended
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