FCA ergonomics proactive approach in developing new cars: Virtual simulations and physical validation

Abstract

Cars’ manufacturing is subject to radical change because of market continuous request of new models developed in few years. Original Equipment Manufacturer and suppliers have to develop more flexible assembly chains, manufacturing services and methods for job planning. And this requires new concepts for process design and for production: the human centered approach to improve manual assembly. In Fiat Chrysler Automobiles, during process design “Digital Manufacturing” and immersive virtual reality have been used in design phase. Holistic ergonomics assessment method as EAWS and ErgoUAS Methods have been used for ergonomic optimization of assembly tasks and for optimal line balancing. Parallel to virtual phase physical assessment on prototypes runs in order to have a physical validation of design/virtual solutions.