Digital human modelling-driven ergonomic risk assessment, workstation redesign, and usability evaluation in a manufacturing assembly line

Abdullah, Zulkeflee and Zainal, Nor Ain Shafikah and Isa, Halim and Md Ghazaly, Mariam and Maidin, Shajahan and Sued, Mohammad Kamil and Md Ali, Mohd Amran and Nordin @ Musa, Nurdiana and Kurniawan, Denni (2026) Digital human modelling-driven ergonomic risk assessment, workstation redesign, and usability evaluation in a manufacturing assembly line. International Journal of Research and Innovation in Social Science (IJRISS), X (III). pp. 8082-8095. ISSN 2454-6186

Text 00119270420262258453152.pdf Available under License Creative Commons Attribution. Download (1MB)

Abstract

This study applies a digital human modelling–driven approach to ergonomic risk assessment, workstation redesign, and usability evaluation in a manufacturing assembly line. Work-related musculoskeletal disorders (WMSDs) remain a major occupational health concern in manufacturing environments, particularly in standing manual assembly workstations. Inadequate workstation design often leads to awkward postures, prolonged static loading, and repetitive movements, contributing to discomfort, fatigue, and reduced productivity. This study evaluates ergonomic risks associated with working postures at a manual insert workstation in an air-conditioner manufacturing company using Digital Human Modelling (DHM) integrated with Rapid Upper Limb Assessment (RULA) and Rapid Entire Body Assessment (REBA). A cross-sectional assessment involving ten female operators was conducted using observational analysis, anthropometric measurement, and the Cornell Musculoskeletal Discomfort Questionnaire (CMDQ). Existing work postures were simulated in CATIA to quantify ergonomic risk levels. Based on identified risk factors, an ergonomically improved workstation was designed and re-evaluated using RULA. Results showed that the existing workstation posed medium to very high ergonomic risks (RULA scores up to 7; REBA scores up to 11), particularly affecting the neck, lower back, and lower limbs. The redesigned workstation reduced the RULA score to 3, indicating a substantial improvement in postural risk. The findings demonstrate the effectiveness of DHM-supported ergonomic interventions in reducing WMSDs risk and highlight the importance of user-centered workstation design in manufacturing settings.

Item Type:	Article
Uncontrolled Keywords:	Digital human modelling, Ergonomics, RULA, REBA, Work‑related musculoskeletal disorders, Standing assembly workstation
Divisions:	Faculty Of Industrial And Manufacturing Technology And Engineering
Depositing User:	Sabariah Ismail
Date Deposited:	13 Jul 2026 06:41
Last Modified:	13 Jul 2026 06:41
URI:	http://eprints.utem.edu.my/id/eprint/29954
Statistic Details:	View Download Statistic

Actions (login required)

View Item