APPLICATION OF ERGONOMICS IN VEHICLE ASSEMBLY - EARLY DESIGN TO ON-SITE ANALYSIS

摘要

This paper describes the ergonomics process of Ford Motor Company European Vehicle Operations Division, starting at the very early design stages of new vehicle programmes, through to the on-site analysis of new work places. Generic manufacturing ergonomics guidelines, combined with evidence-based identification of current ergonomics issues, are input in the early design phase, and influence the design strategy. During the various design stages, virtual analysis tools are used to identify ergonomics hazards, using the Jack software system. Operations are checked for reachability and visibility for the range of population from a 50th percentile female to a 95th percentile male. A static strength evaluation identifies the acceptable force for critical exertions. At the prototype build phase, physical checks of all operations take place, and actual insertion forces of components are measured. Vehicle line heights and manufacturing process allocations are defined, with emphasis on ergonomics. Finally, ongoing ergonomics reviews are conducted in the plant to identify ergonomics issues created by line balancing and allocation, incorrect line heights, or changes in parts or processes. The assessment tools used for this are described.