Business from technology

Human-Machine Systems and Virtual Reality

Improving production flexibility, product quality and shortening time to market, while keeping costs under control in a globally distributed product process, is a significant challenge for companies. VTT's Human-Machine Systems (HMS) knowledge area helps to respond to the challenge by developing safe and efficient industrial systems and workplaces. The core competence combines human-technology interaction, virtual environments and functional simulation. The HMS knowledge area offers a synergistic set of multidisciplinary skills, solid expertise on customer projects and world-grade research competence in virtual environments and human factors engineering throughout the product lifecycle. The HMS knowledge area is a part of VTT’s global G+ competence area of Virtual Products and Production Processes.

Competences, services and industrial cases

Human - Machine interaction at the design phase (various industry fields)

• Machine design for operation and maintenance
  
• Development of a simulator for maintenance operations training
  
• Production line, production layout and workplace design and analysis
  
• Factory layout verification and improvement
  
• Task design and analysis, ergonomics and safety analyses
  
• Vehicular working machines (cabin design, maintenance planning and maintainability design)
  
• Control room for ITER fusion reactor maintenance robots
  
• Aircraft cockpit
  

Case examples of machine design for operation and maintenance

• Sandvik: Cabin design and visibility analysis for underground loader
  
• Metso: Minerals: Maintenance design and training simulation of a rock crusher
  
• Ruukki: Forklift cabin design
  

Case examples for layout and workspace design and analysis

• Rautaruukki: Steel factory layout verification and improvement
  
• Moventas: Windmill gearbox assembly line layout and task design
  
  
  

Tools and methods

Virtual environments and interactive virtual prototyping

• Remote operation in virtual environments (VR)
  
• Training and performance evaluation in VR
  
• Service and maintenance planning in VR
  

Human-centered design and human factors engineering

• Safety and ergonomics analyses of machinery and industrial work environments
  
• Human-centered design, applying participatory approach
  
• Application of digital human models for task and system design
  
• User experience design simulator
  
• Digital human models
  

Functional simulation (e.g. vibration, work sequences, visibility analysis)

Product data and life cycle management (PDM, PLM)

Life cycle assessment (LCA)

Added value and research areas

Human-machine systems knowledge area offers following qualities to its partners and clients

Unique selection of complementary skills: Ergonomics, safety, human-machine systems, machine design, computer science, virtual reality engineering

Internationally competitive applied research in the fields of industrial system design, combining virtual and human factors engineering

Track record of customer projects in Finland and world wide

Our research areas include

• Efficient methods for development of virtual environments
  
• Human-machine interface simulations
  
• User interface design in Virtual Environment
  
• Virtual Prototyping based design process
  
• Product Life Cycle Management
  
• Remote Operation in Virtual Environment
  
• Maintenance work design and testing
  
• Interactive Virtual Prototyping
  
  
  

Benefits

The advantages of applying digital human models, simulation and participatory design method have been reported in multiple industrial cases. Here we provide examples of our past successful references.

• During factory design stage, a significant error in work area was identified and removed. One week was saved from the ramp-up time, giving at least 250 000 euros saving.
  
• Error in material logistics was found at the factory design stage. The error identification produced 150 000 euros saving.
  
• In a factory, 78% hazards and design mistakes were identified during design stage. Based on customer’s estimations savings were about 200 000 euros. 
  
• Improved ergonomics of 20 workplaces in light assembly resulted in less back disorders leading to sick leaves, saving four person months per year.
  
• Error in maintenance hatch design avoided, potentially saving 100 000 euros from re- design and re-installation.
  

Cost efficiency        

• Less physical prototypes
  
• Shortened time to market
  
• Reduced total life cycle costs
  
• "First time correct"
  

User friendly solutions 

• Safer, user friendly products
  
• More ergonomic and comfortable environments
  
• Human centered life cycle thinking
  

Fluent product process

• Better understanding of the complete process
  
• Flexibility and fast adaptation to new challenges
  
• Improved process management
  
• Early elimination of errors
  
  
  

References and experience