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The assessment and optimisation of postural stress and physical fatigue can be challenging and is typically conducted only after the design of manual operations has been finalised. However early assessment of manual operations and identification of critical factors that are deemed outside of an appropriate envelope can avoid the time and costs often associated with re-designing machines and layout for operator work processes. This research presents a low cost software solution based on a simplified skeleton model that uses operator position and workload data extracted from a simulation model used for virtual manufacturing process planning. The developed approach aims to assess postural stress and physical fatigue scores of assembly operations, as they are being designed and simulated virtually. The model is based on the Automotive Assembly Worksheet and the Garg's metabolic rate prediction model. The proposed research focuses on the integration of virtual process planning, ergonomic and metabolic analysis tools, and on automating human factor assessment to enable optimisation of assembly operations and workload capabilities at early design stage

A Lightweight Approach for Human Factor Assessment in Virtual Assembly Designs: An Evaluation Model for Postural Risk and Metabolic Workload