Digital human modeling and CATIA-based simulation for predicting musculoskeletal disorder risks in automotive parts manufacturing

Manual material handling in automotive manufacturing poses significant risks for work-related musculoskeletal disorders. Digital human modelling enables proactive ergonomic intervention before physical implementation. This simulation study evaluated the effectiveness of a CATIA-simulated conveyor workstation in reducing the risk of work-related musculoskeletal disorders among 56 male automotive workers. Following Hierarchical Task Analysis, ergonomic assessments using the Rapid Entire Body Assessment tool for postural analysis and 3D static strength prediction program for L5/S1 intervertebral disc (lumbosacral joint) forces were performed in actual conditions and repeated in a CATIA V5R21-simulated conveyor workstation. The simulated workstation would significantly reduce postural risk scores and decrease both compressive and shear forces on the L5/S1 disc (p < 0.05). Furthermore, it would eliminate high-risk sub-tasks and correct inappropriate postures. Digital human modelling provides an effective proactive approach for ergonomic design, significantly mitigating work-related musculoskeletal disorders risks prior to physical implementation in manufacturing environments.