Ergonomic Risk Assessment Score Calculation for Digital Human Models
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Solution Overview
Problem
Existing ergonomic assessment methods fail to provide a comprehensive, overall assessment of ergonomic risk across production lines, requiring manufacturing engineers to manually prioritize and address multiple scores generated by static posture analysis tools.
Innovation Solution
A computer-implemented method calculates a weighted average of posture risk levels for digital human models performing tasks, allowing for ergonomic risk assessment at various levels (factory, production line, workstation, and task) by modifying weights based on risk levels, joint at risk, and risk type, enabling prioritization of ergonomic improvements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If multiple ergonomic assessment scores are generated for different postures and tasks, then comprehensive ergonomic evaluation is achieved, but it becomes difficult to determine which problems to prioritize and where to invest resources
Solution Approach 1:
The patent combines multiple individual ergonomic assessment scores into a single aggregated ergonomic risk score for each workstation. This aggregation merges numerous discrete measurements (from multiple digital human models, tasks, and postures) into a unified metric that maintains comprehensive evaluation capability while simplifying prioritization decisions for manufacturing engineers.
Solution Approach 2:
The patent introduces an intermediary aggregation layer between the detailed posture analysis tools and the decision-making process. This intermediary computes combined ergonomic risk scores that translate complex multi-dimensional assessment data into a single prioritization metric, serving as a bridge between detailed measurement and actionable insight.
2Adaptability or versatility
If detailed ergonomic analysis is performed at multiple levels (factory, production line, workstation, task), then comprehensive coverage is achieved, but the amount of data and complexity of prioritization increases significantly
Solution Approach 1:
The patent segments the ergonomic assessment system into hierarchical levels (factory, production line, workstation, task) with aggregated ergonomic risk scores computed at each level. This segmentation allows comprehensive multi-level evaluation while enabling manufacturers to focus on specific levels of granularity as needed, reducing the time required to prioritize improvements at any given level.
Solution Approach 2:
The patent adds a hierarchical dimension to ergonomic assessment by computing aggregated scores at multiple organizational levels simultaneously. This dimensional approach transforms the prioritization problem from analyzing numerous individual task scores to comparing aggregated workstation, production line, and factory-level scores, significantly reducing the complexity of identifying priority areas.
3Measurement precision
If static posture analysis tools are used to assess ergonomic risk, then specific posture scores can be obtained, but no overall assessment for the production line or factory can be derived
Solution Approach 1:
The patent extends the useful action of ergonomic assessment from individual static postures to continuous aggregated evaluation across entire production lines and factories. By continuously aggregating individual posture scores into workstation-level and facility-level metrics, the system maintains the precision of static analysis while enabling comprehensive overall assessment that guides productivity improvements.
Data Source
AI summary
Embodiments assess ergonomic risk of causing harm to a worker in a workplace. One such embodiment receives an indication of posture risk level for each of a plurality of digital human models performing a task. In turn, a weighted average of the received indications of posture risk level is determined. This determined weighted average is indicative of ergonomic risk to a real-world worker performing the task in a workplace. Embodiments consider consecutive risk through modifications to weights used in the determining the weighted average.