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In spring 2001 ThyssenKrupp Gerlach GmbH has commissioned a new production line for manufacturing crankshafts. Although nearly automated packaging for shipping has to be done manually due to customer demands. The final layout of the corresponding workplace is based on a 3D man model (ANTHROPOS ErgoMax), which has been used for virtual design and evaluation. The ergonomic analyses of the preliminary workplace layout with the 3D man model showed serious problems when depositing the crankshafts. Therefore different workplace layouts related to this work element were developed, compared and rated. Finally the most ergonomic solution was found as a combination of height adjustment and a 180° turn of the transport containers to optimize working conditions. In addition vision analyses and studies where to position the controls were carried out using the man model.

The layout of special-purpose vehicles for global distribution has to ensure that all products can “fit” worldwide operators. Since spring 2001, BOMAG has implemented RAMSIS software, a CAD-based 3D man model, into the conception and design phases for their construction machines. First applications comprised the ergonomic optimization of the configuration and layout for driver's cabs and control elements, specifically related to a small single drum roller, a tandem roller, a big refuse compactor and in addition maintenance issues. First results of the enhanced design process highlighted the benefits of applying such ergonomic tools, providing anthropometrical and additional human data for consideration in the layout of workplaces.