Factor the human element into design using digital humans.

Countless organizations in a variety of industries are facing the same problem: the human element is not being considered early or thoroughly enough in the design, assembly and maintenance of products. More importantly, this is having a devastating impact on cost, time to market, quality and safety.

For a growing number of organizations, however, factoring the human element into design, manufacturing and maintenance is no longer a problem; it's a competitive advantage. These organizations are using Jack to realize benefits such as:

• Shorter design time
• Lower development costs
• Improved quality
• Increased productivity
• Enhanced safety
• Heightened morale

Keep reading to learn more about the challenges, issues and, most importantly, the benefits related to human simulation in design, manufacturing,maintenance and training.

Digital Humans in Product Design

During the product design phase, organizations face several key challenges related to the physical attributes and behavior of humans. They need to:

• Develop products centered on humans and evaluate designs based on ergonomic factors.
• Account for different sizes and shapes of people.
• Consider human factors in design before building physical prototypes.

Human simulation allows you to answer these questions:

• Positioning and comfort -- Is your design optimized for user comfort, visibility and access to controls?
• Visibility -- What can people of different sizes see when they operate your equipment or vehicle?
• Ingress and egress -- Can your target population easily climb in and out of equipment or vehicles?
• Reaching and grasping -- Are controls placed so everyone can reach and operate them?
• Foot pedal operation -- Can people of various sizes comfortably operate foot pedals?
• Multi-person interaction -- How do multiple people interact with your product?
• User maintenance -- Can everyone perform maintenance tasks for your products, like changing a tire?
• Strength assessment -- Does operating your product require inordinate strength or create the potential for injury?

By using human simulation in product design, organizations can expect to realize these benefits:

• Faster time to market -- More design iterations in less time
• Higher product quality -- Improved human "fit"
• Reduced development costs -- Digital mockups versus physical prototypes
• Safer products -- More-thorough analysis of user safety
• Improved productivity -- Enhanced automation of development process

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Digital Humans in Manufacturing

Organizations face several key challenges related to the physical attributes and behavior of humans in manufacturing. They need to:

• Bring factories on-line faster
• Optimize manual workflow
• Improve worker safety
• Lower workers' compensation costs
• Reduce downtime and retraining costs

In the manufacturing phase of the product lifecycle, human simulation allows you to answer these questions:

• Workcell layout -- Are machines and other equipment positioned to optimize cycle time and avoid hazards?
• Workflow simulation -- Are your manufacturing processes designed to eliminate inefficiencies and ensure optimal productivity? Can you simulate the capabilities (or limitations) of humans in your "jobs-per-hour" equation?
• Assembly accessibility -- Can all assembly personnel access parts and equipment needed to assemble your products?
• Reaching and grasping -- Can your workers effectively use all hand tools needed to perform manual tasks?
• Safety analysis -- Can all of your assembly tasks be performed safely?
• Strength assessment -- Does any assembly task require inordinate strength or expose people to the risk of injury?
• Lifting -- Do all lifting tasks in your factories and warehouses fall within NIOSH strength guidelines?
• Energy expenditure -- How much energy will your workers expend over time as they perform repetitive tasks?
• Simulation-based training -- How can you use real-time simulation and virtual reality to train workers?

By using human simulation in manufacturing, organizations can expect to realize these benefits:

• Fewer work-related injuries
• Reduce workers' compensation costs
• Less costly compliance with worker health and safety regulations
• More productive work environments
• Improved employee morale

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Digital Humans in Maintenance

Organizations face several key challenges related to the physical attributes and behavior of humans in maintenance. They need to:

• Reduce lifecycle costs by lowering maintenance requirements
• Design products to optimize maintainability
• Ensure that technicians can access parts and tools
• Anticipate strength and time requirements for maintenance tasks

In the maintenance stage of the product lifecycle, human simulation allows you to answer these questions:

• Maintenance accessibility -- Is there sufficient space for technicians to perform maintenance tasks, including space for hands, arms and tools?
• Part removal & replacement -- Can all technicians efficiently install and remove parts?
• Visibility -- What exactly can technicians see when they perform specific maintenance tasks?
• Reaching and grasping -- Can technicians effectively use the hand tools required for all maintenance tasks?
• Strength capability -- Does the strength required for a specific maintenance task make it difficult for any of your technicians to perform?
• Lifting -- Are technicians being placed at risk of injury during any lifting procedures?
• Safety analysis -- Can maintenance tasks be performed safely by all technicians?

By using human simulation in maintenance, organizations can expect to realize these benefits:

• Less design rework and retrofit
• Faster turnaround on maintenance jobs
• Lower training costs
• Lower product lifecycle costs
• Greater customer satisfaction
• Improved competitiveness

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Digital Humans in Training

Organizations face several key challenges related to the physical attributes and behavior of humans in training. They need to:

• Lower the cost of training manufacturing and maintenance personnel
• Train people without the need for physical prototypes or actual equipment
• Train people in multiple locations simultaneously

In the maintenance stage of the product lifecycle, human simulation allows you to answer these questions:

• Manufacturing training -- How can you use real-time simulation and virtual reality to train assembly workers on the job site?
• Maintenance training -- How can you leverage computer technology to train maintenance personnel from multiple locations?

By using human simulation in maintenance, organizations can expect to realize these benefits:

• Lower training costs
• More cost-effective training of geographically dispersed personnel
• Great student retention of information
• Improved workplace safety
• Improved worker morale

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