The employment of intelligent tools in production, such as the new area of wearable robotics, the Exoskeletons, represents valuable and promising technology to reduce the physical stress and increase innovation, productivity and workplace safety. The challenge of realizing these advanced manufacturing environments with integrated Exoskeletons is represented by missing design and planning methods required to equip future workplaces with this enabling technology. The integration of Exoskeletons in logistics and production activities creates a new hybrid type of workstation that has to be designed according to a scientific approach. The article presents the first steps in developing an innovative approach to planning and optimizing intelligent working environments with integrated adaptive Exoskeletons. The topic harmonizes three main areas of research: a) production technologies and holistic planning of production processes; b) ergonomics, safety and security of workers in production environments and c) configuration based on the components of the new type of wearable robotics, the Exoskeletons.The validation of this approach is provided through the creation of digital human/Exoskeleton models combining digital Exoskeleton with various digital human models. The Digital Twin of the human/Exoskeleton system is the heart of a holistic design and optimization process that aims to assess the appropriateness of the selected Exoskeleton by simulating the tasks performed and adapting the simulation parameters.An exemplary validation case in one of the most innovative and dynamic sector, the construction sector, demonstrates the applicability of the model. A guideline for migrate the model in other industry sectors is provided, as well.
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