"It is much cheaper to design in ergonomic features than it is to go back and modify existing designs," says Chris McIntyre, president of Ergonomics at Work Inc. (Kitchener, ON). "Software allows for what-if scenarios regarding risk of injury, productivity, workstation dimensions and other important factors."
Automakers are leading the charge to simulated assembly. General Motors Corp. (Detroit) has developed a program called Virtual Factory that manufacturing engineers use to address ergonomic issues before they occur on the assembly line. By creating virtual assembly plants with computer simulation, engineers test how tooling and fixtures interact with assemblers. "The technology is key to reducing vehicle development times, reducing costs, improving product quality and enhancing workplace safety," says Guy Briggs, vice president and general manager of GM vehicle manufacturing.