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The introduction of new information and communication technologies (ICT) in factory environment is leading the world of manufacturing industry to a change. Indeed, we talk about Industry 4.0, the fourth industrial revolution, that facilitates the vision of a Smart Factory in which systems become cyber-physical, interact between themselves, monitor and validate physical processes, creating a virtual copy of the physical world and making decisions based on complex numerical analysis. Virtualization and simulation of production processes generate several benefits, in terms of costs and time, optimizing the assembly line design and studying human-machine interaction. Regarding the last topic, this paper proposes an innovative method for ergonomic analysis of workplaces on automotive assembly lines in a virtual environment. The method can represent an innovation for human-centered design of workplace in developing new products, reducing costs and improving job quality thanks to a preventive ergonomic approach.

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. The aim of this work is to present an experimental wearable inertial motion tracking system, developed at the Dept. of Engineering of the University of Campania “Luigi Vanvitelli” in collaboration with Linup S.r.l., composed by several low-cost inertial measurement units (IMU). The system allows to estimate the orientation of selected human body segments and to analyze the postures assumed during the working tasks. To increase the flexibility of use, the system is highly modular: it’s composed by 4 independent modules in full-body configuration, each one made of 3 or 4 inertial units. In this paper, the overall system is presented, supported by several test cases, carried out in Fiat Chrysler Automobile (FCA) assembly lines, to test the system reliability in industrial environments. Furthermore, an automatic posture analysis code is presented to evaluate the postural critical issue of the workplaces.

The study of human factors is fundamental for the human-centered design of Smart Workplaces. IIoT (Industrial Internet of Things) technologies, mainly wearable devices, are becoming necessary to acquire data, whose analysis will be used to make decision in a smart way. For industrial applications, motion-tracking systems are strongly developing, being not invasive and able to acquire high amounts of data related to human motion in order to evaluate the ergonomic indexes in an objective way, as well as suggested by standards. For these reasons, a modular inertial motion capture system has been developed at the Department of Engineering of the University of Campania Luigi Vanvitelli. By using low cost Inertial Measurement Units – IMU and sensor fusion algorithms based on Extended Kalman filtering, the system is able to estimate the orientation of each body segment, the posture angles trends and the gait recognition during a working activity in industrial environment. From acquired data it is possible to develop further algorithms to online asses ergonomic indexes according to methods suggested by international standards (i.e. EAWS, OCRA, OWAS). In this paper, the overall ergonomic assessment tool is presented, with an extensive result campaign in automotive assembly lines of Fiat Chrysler Automobiles to prove the effectiveness of the system in an industrial scenario.