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Ford Motor Company's Use of Digital Human Modeling

For over a century, Ford Motor Company has been at the forefront of automotive innovation. As the industry evolved, Ford recognized the pressing need for modern solutions to age-old challenges – chiefly, the ergonomic safety and efficiency of its assembly lines.




The Challenge:


  1. Rising Injury Rates: By the early 2000s, Ford noted an uptick in musculoskeletal injuries among assembly line workers.

  2. Diverse Workforce: Ford's global workforce comprises individuals of different sizes, strengths, and work habits. Standard solutions weren't universally effective.

  3. Cost Implications: Physical prototyping and reactive ergonomic adjustments were proving costly – in terms of both financial outlays and time-to-market for new models.


The DHM Solution: Ford turned to Siemens' Jack and Process Simulate Human software, powerful tools in the realm of digital human modeling.


Features and Initiatives:


  1. Virtual Build Events (VBE): Before the launch of a new model, Ford conducts VBEs, where the entire assembly process is simulated digitally.

  2. Global Posture Study: Using Jack, Ford conducted a study encompassing its global workforce to develop accurate virtual manikins. This ensured diverse worker profiles, from Asia to America, were considered in ergonomic planning.

  3. Real-time Feedback Integration: Workers wore motion sensors, with data fed into the DHM tools. This captured real-world movement and strain, providing invaluable insights for digital simulations.


Quantitative & Qualitative Results:


  1. 60% Reduction in Injuries: Within five years of integrating DHM into its ergonomic strategy, Ford reported a 60% reduction in assembly line worker injuries.

  2. $10 Million Annual Savings: By pinpointing and resolving ergonomic issues during the design phase, Ford saved an estimated $10 million annually by avoiding post-launch modifications.

  3. Enhanced Employee Morale: With reduced strain and injuries, Ford noted a marked improvement in worker morale and job satisfaction.

  4. Faster Time-to-Market: Digital prototyping via DHM reduced the design-to-production cycle by several weeks.


"The introduction of digital human modeling has been a game-changer. We're not just saving costs; we're safeguarding our most valuable asset: our people." - Dr. John Sheltzer, Senior Ergonomist, Ford Motor Company.


Ford Motor Company's deep dive into digital human modeling offers a paradigm for the automotive industry. By leveraging technology to proactively address ergonomic challenges, Ford has showcased the tangible benefits of marrying human well-being with technological innovation.


As industries globally recognize the importance of digital human modeling, there's a growing demand for expert guidance. Ergo Dynamic Solutions, with its proven expertise, has directly worked with automotive companies, including Ford, Chrysler, and GM, in harnessing the power of Siemens' Jack and Process Simulate Human software.


If you're keen to explore the transformative potential of digital human modeling for your business, don't hesitate to contact Ergo Dynamic Solutions. With our deep industry knowledge and hands-on experience, we're perfectly positioned to guide your journey towards ergonomic excellence.


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