Optimized Manual Processes in Automotive Production

A module-based approach for the efficient creation of work system simulations

JournalIndustry 4.0 Science
Issue Volume 42, 2026, Edition 3, Pages 48-55
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Abstract

In the manufacturing industry, the integration of digital human models into the product development and manufacturing process is becoming increasingly important. Particularly in assembly, which is characterized by a high proportion of manual tasks, motion simulations enable a realistic representation of human work and thus make a significant contribution to the evaluation of motion economy, process validation, and efficiency improvement. However, widespread application in production planning faces various challenges, such as the high initial effort required to create human simulations as well as volatile planning conditions. This article presents a practice-oriented solution from the automotive assembly sector that enables the creation of simulations with reduced effort as well as their early and consistent use in the planning process.

Keywords

Article

The automotive industry is undergoing a period of profound transformation characterized by increasing product diversity, shorter product lifecycles, and rising demands for flexibility and sustainability [1]. Among other things, these developments are leading to ever-increasing complexity in production planning and presenting new challenges for planning managers. The need for end-to-end, digitally supported planning is correspondingly high in order to efficiently manage the flow of information between development, planning, and production and to make informed decisions as early as the initial development phases [2]. Despite increasing automation, assembly is still characterized by …

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Solutions: Assembly

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