Lidia Ghibaudo's research while affiliated with Fiat Chrysler Automobiles Group and other places

The focus of this study is on a comprehensive digital twin illustrating the assembly of a high-tension cable in an electric vehicle. This involves the integration of two software programs, IPS Cable Simulation and IPS IMMA (Intelligently Moving Manikin in Assembly), to simulate the cable assembly and analyze ergonomic factors. The study uses the vehicle geometry and task sequence of Stellantis on a hypothetical use case of an extreme assembly line with the vehicle raised and the operator performing the activity underbody. The simulation of the cable assembly analyses extension-compression and torsion behaviors, ensuring compliance with acceptable limits. Anthropometric variations among operators are considered using IPS IMMA's module to create a family of manikins representing the global Stellantis workforce. Ergonomic analysis with the EAWS tool identifies risk factors for operators of different anthropometries. Additionally, a comparison is made on task time between the MTM-UAS methodology and IPS simulation's biomechanically modelled time. Results indicate a successful integration of IPS Cable Simulation and IPS IMMA, creating a digital twin that accurately simulates the operator's task with the high-voltage cable. The study emphasizes the importance of biomechanical models in understanding issues related to reachability, incongruous postures, and their impact on task time, contrasting with predetermined time approaches. In the current landscape of electrified vehicles, where there is a noticeable increase in the dimension and number of the cables, and of autonomous vehicles, where packaging challenges arise from redundancy requirements and the growing reliance on virtual verification, comprehensive and realistic dynamic simulations will become increasingly vital.

In the present day, manufacturing companies are constantly facing new challenges, mostly deriving from the possibilities offered to industry by the fourth industrial revolution. New capabilities and services are available for customers and companies by advanced technologies and interconnections, changing the way we live, work and relate to one another. A promising example of Human-Robot Collaboration is the exoskeleton, a wearable device that interacts with the users to reduce the strain associated to the repetitive tasks present in the manufacturing environment. Fiat Chrysler Automobiles (FCA) (The company merged with PSA creating Stellantis N.V. in January 2021. Abstract was submitted at an earlier stage.), a multinational corporation operating into four (4) Regions: EMEA, North America, LATAM and APAC, had the opportunity to benchmark and test exoskeletons in the different Regions. The focus of the present paper is to present a collaborative approach within Regions on exoskeletons application and feasibility studies including experimental tests, key performance indicators and legal requirements. Main aspects and results are presented together with the open questions.

Since the early development for health purposes in 1950s, motion tracking systems have been strongly developed for several applications. Nowadays, using Micro Electro-Mechanics Systems (MEMS) technologies, these systems have become compact and light, being popular for several applications. Looking at the manufacturing industry, such as the automotive one, ergonomic postural analyses are a key step in the workplaces design and motion tracking systems represent fundamental tools to provide data about postures of workers while carrying out working tasks, in order to assess the critical issues according to ISO 11226 standard.

This study is part of a project carried out in Fiat Chrysler Automobiles with the aim of introducing innovation and Industry 4.0 technologies in workers’ training. Nowadays, the training is performed using a system, called “Manufacturing Training System” (MTS), composed by three different areas: a document area in which there are step method procedures, quick kaizen and operation cards for each work phase; an ability corner with tools useful to perform activities and a simulated production line on which the operator can practice.

This study is a part of an innovation project carried on in ErgoLab, the ergonomics laboratory of FCA in Turin, with the aim of evaluating the use of a passive exoskeleton for upper limbs in automotive manufacturing tasks. The introduction of new technologies into a production environment is not always effective, because workers often don’t use them. It is therefore important that future users accept this innovation.

Wearable exoskeletons are currently evaluated as technological aids for workers on the factory floor, as suggested by the philosophy of Industry 4.0. The paper presents the results of experimental tests carried out on a first prototype of a passive upper limbs exoskeleton developed by IUVO. Eighteen FCA workers participated to the study. Experimental tests were designed to evaluate the influence of the exoskeleton while accomplishing different tasks, both in static and dynamic conditions.

Italian legislation on the subject of Workers’ Health and Safety recalls the ISO standards for the ergonomics analysis and mentions the OCRA method as ‘preferred’ for risk assessment of upper limbs overload. Over the years, other methods for ergonomics risk assessment not currently mentioned in ISO Standards, were developed. As for example, EAWS method – proposed by International MTM network for ergonomic design and analysis of workstations – is greatly adopted by automotive OEMs because of its integration in the ErgoUAS system that allows to define the sequence of tasks and the time needed to perform related to the biomechanical load. This paper presents the “Cut Off” Project developed to define a risk assessment procedure for upper limbs based on the combined use of EAWS section 4th and OCRA Checklist. “Cut off” are a set of criteria, related to the main risk factors for upper limbs musculoskeletal disorders, characterized by threshold values based on EAWS section 4th. The aim of the procedure is to apply EAWS section 4th to all manual workstations during both design and risk assessment phase and to analyze with OCRA checklist only workstations, characterized by the overcome of one or more thresholds based on EAWS factors. The procedure is going to be constantly monitored and possibly improved by new data collection.

The paper describes the testing activity carried out on a commercial passive lower limb exoskeleton: the Chairless Chair, a wearable sitting support that allows workers to switch between a standing and a sitting posture. Tests were carried out with FCA workers who volunteered for the study. Laboratory trials served to familiarize the users and to obtain an initial feedback on the usability of the device in the assembly line. At a second step, virtual modelling of a few static postures was carried out, reproducing the anthropometry and the postural angles of the worker while using the exoskeleton. A main output of the model is the estimate of what forces are exchanged between the subject and the exoskeleton. In the case of the lower limb exoskeleton, an important parameter to consider is the percentage of the subject’s weight that is sustained by the exoskeleton frame. The higher is this percentage, the lower will be the strain on the subject’s lower limbs. First comparison between experimental and simulated results showed good agreement and auspicious advantages of exoskeletons in relieving the strain on workers.

Biomechanical overload represents one of the main risks in the industrial environment and the main possible source of musculoskeletal disorders and diseases. The aim of the this study is to introduce new technologies for quantitative risk assessment of biomechanical overload, by integrating surface electromyography (sEMG) with an innovative motion-capture system based on inertial measurement units (IMU).

Exoskeletons are part of the technological and organizational innovation sought by the fourth industrial revolution to support and re-launch the manufacturing area. In the present study, we described the experimental protocol designed to test the usability and acceptance of an upper limbs passive exoskeleton. In total, 42 workers from FCA plants volunteered to participate in the research study. The testing campaign included static and dynamic tests aimed at evaluating the potential benefit of the exoskeleton (lessen muscle strain, higher comfort rating and dexterity) vs. possible restrictions to movements and work-device interactions in tasks resembling work activities. Open questions remain on how to assess the biomechanical workload risk, especially in the design phase, for which holistic methods like EAWS are needed.