1. VIRTUAL ERGONOMICS VERIFICATION
Innovative, unique, cost efficient, reliable and sustainable solution
for labour and production optimisation and safety
REFERENCE CASE
ViVeTech Ltd.
Béla Batizi
Director of sales and marketing
bela.batizi@vivetech.com
www.vivetech.com
For more information please contact:
TÜV Rheinland InterCert Ltd.
Gergely Hidas
Virtual Testing and Verification Laboratory project manager
gergely.hidas@hu.tuv.com
www.tuv.com
ABOUT TÜV RHEINLAND
Founded over 140 years ago, TÜV Rheinland is one of the world’s leading independent testing organisations
for technical services. The aim of TÜV Rheinland is to provide sustainable, high standard quality and safety
solutions to different challenges created by the interaction of humans, technology and the environment all over
the world, and in almost all areas of our lives. This is a guiding principle that also expresses our high level
commitment to society and to ecology.
As one of the leading innovative service provider companies worldwide we are aware that employees are the
most valuable assets on the road leading to success. For that reason, our experts - physicians, psychologists
and labour safety engineers - provide support to enterprises in the implementation of workplace health and
safety strategies, from surveys through personal health checks to the provision of fire protection requirements.

2. INITIAL POSITION AND EXPECTATIONS
AUDI Hungaria Motor Ltd. lays special focus on the ongoing testing of its individual workplaces along the
aspects of labour safety, efficiency, time schedules and ergonomics at its V6 Diesel production line. Ongoing
ergonomics tests are useful and reliable according to feedback received from those working at the production
lines, but data recording is time consuming, and the results and the recommendations obtained are difficult to
interpret. The high costs of film production, data collection and analysis were also defined as a problem, along
with subjectivity being mentioned.
The partner specified the followings as objectives of key importance for the project: quickness, reliability,
objective data collection and the professional evaluation thereof.
SOLUTIONS, RESULTS
Several ergonomic deficits were identified
Based on the suggestions the workplace was redesigned, a new workplace layout was developed.
ERGONOMIC OPTIMISATION BY VIRTUAL HUMAN ENGINEERING FOR
ONE OF THE WORLD’S LEADING AUTOMOBILE MANUFACTURERS
Virtual Ergonomics Verification service represents an innovative solution for the assessment and
evaluation of work processes with the aim to improve productivity, efficiency and quality, and to reduce
occupational diseases, sick-leave and the fluctuation of employees.
BASIC DATA
Customer AUDI Hungaria Motor Ltd.
Cooperation partner ViVeTech Ltd., Virtual Verification Laboratory Platform provider
Schedule November 2013 - June 2014
Location Hungary, Győr
Services
CORRECTIVE ergonomics analysis: ergonomics analysis and
optimisation of production line work process
CONCEPTIVE ergonomics analysis: support of production planning by 3D
models in the design phase
Regulatory environment National and international ergonomics standards and provisions
METHODOLOGY
Virtual Ergonomics Verification service comprises two forms of testing:
DID you know?
As the majority of costs is incurred in the
development phase already, Virtual Test and
Verification, as a Frontloading Concept, and in
view of cost efficient intervention in due time,
provides an opportunity for the correction
of potential errors in the early phase of
development already.
By the Virtual Verification Ergonomics service,
the following aspects arising out of the non-
conformity of the workplace and the work
process may be prevented, reduced and
eliminated:
productivity, efficiency related losses
quality related deficiencies
occupational diseases, sick-leave
employee fluctuation
The human modelling used in the course of the
analyses may be performed with models of a
build corresponding to anthropological scheme
from any part of the world.
it disposes of an anthropometric database covering
the entire world
its most frequently used analyses in respect of the
detection of the reason of discomfort are: RULA,
OWAS, NASA-OBI and visibility analysis
CusTomeR aDVanTaGes
By the use of the human model of the 3D
designs and the ergonomics software, we
provided the following support in respect of
workplaces already in operation:
Analysis and correction of workplaces to eliminate
and improve unsuitable ergonomics design
Increase of the efficiency of productivity
Improvement of production quality
Reduction of working time losses attributable to
health risks and of the fluctuation of employees
Immediate elimination of parameters hindering work
processes and the performance by employees
CoRReCTIVe anaLysIs
Ergonomics analysis and optimisation of
activities and work processes at the production
line already in operation.
Objective data collected by an inertial 19-sensor
kit (9DOF): head, trunk, hand, lower arm, upper arm,
leg movements
Sensor kit suits industrial environment and can be
tied to the employee’s body in 5 minutes: objective
and fast measurement without stopping production
Conditions of load regarding individual muscles and
joints projected to the entire working time analysed
Distance covered/steps taken during work are recorded
Reachability distances, over reach distances,
frequencies are considered
Anonymity of subjects and data security are ensured
ConCePTIVe anaLysIs
Support of production planning in the design
phase by means of virtual verification and
optimisation before the production line is built.
Import of 3D plans and/or generation of 3D graphic of
the workspace or production line
Creation of kinematic model of staff members to be
analysed based on “takt-time” work instruction
Objective parametric evaluation of the planned work
process against DIN and ISO standards
Using worldwide anthropometric population
databanks: simulations can be carried out on various
type of person
Visibility, Body Forces and Discomfort Analysis,
Collision detection, RULA, OWAS, EAWS, APSA
methods and more
Prediction of body movements with inverse biomechanics
InDusTRIaL moTIon CaPTuRe
The motion capture sensor set is suitable
for industrial use without the need for
cameras.
The full body sensor set is easy to put on
and take off, thus data aquisition can be
done in 15 minutes.
Real-time analysis is also possible.