Colossal Tooling Design: 3D Simulation for Ergonomic Analysis

In manufacturing, ergonomics and human factors issues must be considered during the design and utilization phases. These applied human factors concerns include but are not limited to, reach ability, visibility, lift factors, kilocalorie usage, repetitive motion, ventilation, lighting, and many more. When the tool size becomes colossal, say 35 feet or more in diameter and 90 feet or more in length; and the tool weights an estimated 200 tons, these normal human engineering factors become critical to the safety and health of the workers (see Figure 1). Schaub, et al, (1997) stated that preventive health care is one of the basic challenges facing ergonomics.