A Digital Ergonomics Framework for Preventive Workstation and Work-Process Optimization Using OWAS-Based Risk Assessment

Ergonomic workstation design is essential for improving the fit between workers, tasks, and the work environment while reducing the risk of work-related musculoskeletal disorders. The Ovako Working Posture Analysis System (OWAS) is widely used for ergonomic risk assessment; however, its conventional application to dynamic work can be inefficient because numerous working postures must be observed and evaluated. Moreover, conventional ergonomic design often requires multiple physical mock-ups, while motion-capture technologies such as Kinect are generally applied to existing work conditions, limiting their use for preventive evaluation during the design stage. This study proposes a digital ergonomics framework integrating workstation modeling, work-process simulation, and OWAS-based risk assessment for preventive ergonomic optimization. Digital models of the workstation and work activities were developed to simulate worker postures and identify potentially hazardous conditions before physical implementation. OWAS was used to classify postural risks and determine the required corrective actions. Workstation configurations and work procedures associated with higher risk levels were iteratively modified and reassessed in the digital environment. The results demonstrate that the proposed framework can identify and reduce ergonomic risks during the design stage without extensive physical prototyping. Higher-risk postures were mitigated through iterative modifications of workstation configurations and work procedures. This framework provides a systematic preventive approach for integrating ergonomic assessment into workstation and work-process design, supporting safer working conditions while improving the efficiency of the ergonomic design process