3rd TAGRA

Motion capture systems enable ergonomic risks to be assessed based on actual working conditions by recording operators’ movements during work. This study aimed to ergonomically improve a workstation where repetitive assembly operations are performed. First, a standard workstation was established, and operator movements were recorded using the Xsens system and transferred to the Siemens Process Simulate v2502 environment. Subsequently, the worktable height (94, 85, and 82 cm), the position of the parts rack, and the arrangement of material containers and work equipment on the table were examined in three separate scenarios. The scenarios were evaluated using the OWAS, RULA, and REBA methods, as well as analyses of estimated recovery time and the time-dependent variation in muscle strain. The arrangements found to be appropriate based on the analyses were combined to create an improved workstation. In the reference layout, 82.95% of the OWAS scores were classified as Category 4 and 17.05% as Category 3, whereas all scores in the improved layout were classified as Category 2. At the point when the two-handed reaching task was examined, the RULA score, which was 7 for both arms in the reference layout, decreased to 5 for the left arm and 4 for the right arm; similarly, the REBA score, which was 8 for both arms, decreased to 5 and 4, respectively. These findings indicate that digital ergonomic analyses supported by motion capture data can contribute to improving individual working conditions and developing operator-specific work standards.