Högskolan i Skövde

The shift towards electric vehicle production has introduced new manufacturing challenges, particularly in tasks that require operators to handle flexible components such as electrical wire harnesses and high-voltage cables. Assembly tasks such as picking, carrying, deforming, and mounting flexible components are usually performed by operators and can result in high force demands, affecting both operator well-being and production efficiency. Ensuring that these work demands do not exceed an operator’s physical capacity is essential for maintaining a sustainable work environment, improving worker well-being, and reducing risks of work-related musculoskeletal disorders. This paper addresses this challenge by simulating and evaluating a real-world use case at Volvo Cars AB, where operators manually install electrical wire harnesses in an automotive assembly station. The study integrates the Arm Force Field method within a DHM tool to compare forces demanded by the assembly task to force capacity of the operators. Additionally, RULA and REBA are used to evaluate postural risks during the assembly. The simulation estimates force demands for picking, carrying, deforming, and mounting the harness. By analysing the ratio between work demand and human capacity, this study provides insights into how DHM tools can assist engineers and ergonomists to proactively assess assembly work of flexible objects, in turn assisting workstation design and supporting sustainable manual assembly conditions.