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Musculoskeletal disorders are some of the most frequent manual work disorders. Employers worldwide pay high costs for their treatment and prevention. We present an innovative method for designing an ergonomic workplace. This method uses new technologies and supports not only ergonomics, but also a general improvement in the designing of the manufacturing process. Although many researchers claim that there is a huge potential for using new disruptive technologies like virtual reality and motion capture in ergonomics, there is still a lack of a comprehensive methodological basis for implementing these technologies. Our approach was designed using the expert group method. We can validate the manufacturing process and the ergonomics using a motion capture (MoCap) suit and a head-mounted display (HMD). There are no legislative restrictions for the tools which are used for ergonomic analyses, so we can use our outputs for workplace scoring. Firstly, we measure the anthropometrics of the proband. Then the proband is immersed in virtual reality and they go through a manufacturing process during which ergonomics data are collected. The design of a particular workplace or multiple workplaces can be validated based on the reactions, measurements, and input in real-time. After processing the data, the workplace can be adjusted accordingly. The proposed method has a time and economic benefit for workplace design, optimisation of workplace ergonomics, and shortens the time required for designing the production line layout. It also includes optional steps for validation using conventional methods. These steps were used for method validation on a representative workplace using on-site experiments. We validated it on a group of 20 healthy operators working in automotive production (age 22 to 35). A comparison study describes the classic methods of workplace ergonomics evaluation, compares the classic evaluation using biomechanical analysis, modern evaluation using a MoCap suit, and connection with virtual reality. We have proved the validity of the method using the comparison study. The results also showed other potential issues which can be further examined: like the role of peripheral vision or haptic feedback.

Ergonomic Design of a Workplace Using Virtual Reality and a Motion Capture Suit