One-Fits-All vs. Tailor-Made: User-Centered Workstations for Field Assembly with an Application in Aircraft Parts Manufacturing

Abstract

Field assembly of large components for aircraft, ships, trains or big machinery is often done in a rather unstructured environment, with little concern for the individual needs of the involved personnel. Confronted with a shortage of qualified personnel and a generally aging workforce, workstation designers need to put more emphasis on improving ergonomics and allowing for individual adjustments and support for a particular worker. Human factor engineering traditionally uses a “percentile-approach” to work-design, preventing an exact adjustment to the ergonomic needs of particular users. New technological advances provide opportunities for major improvements; novel assistance and information systems allow the accommodation of the needs of an increasingly diverse assembly workforce, while minimizing overall physical and mental stress.Based on a recently developed synopsis of options for individualization of assembly workstations, an example of an application in field assembly is being presented and illustrated by a full-scale demonstrator for the assembly of large scale composite parts for the aerospace industry. The pilot-installation combines a projector-based augmented reality environment for dynamic worker-information with automated operator position tracking and field of vision positioning. Finally, a comprehensive concept, that includes other dimensions of individualization, is presented.