In industrial production, the digitalization of planning and setting up processes has proven to be enormously useful. Simulation can be used to check processes and requirements virtually at an early stage in order to leverage efficiency potential. However, there is still room for optimization even when using appropriate tools.Machines that enable flexible applications as well as stationary and mobile robots have taken over more and more tasks in production halls in recent years. However, the human factor is still indispensable. This is because some tasks can be carried out faster and more reliably by skilled workers than their mechanical counterparts. Sometimes a division of tasks also proves to be the most efficient method - keyword human-robot collaboration (HRC).
Just like purely automated processes, processes that are wholly or partly based on manual activities must also be checked for efficiency and potential problems. Ergonomic workstations and intuitive human-machine interfaces (HMI) are just as much a part of the influencing factors as the timing of upstream and downstream processes, such as material supply, the speed of an assembly line or the cycles of intralogistics, for example by means of automated guided vehicles (AGVs).
Simulation of manual processes
The tools of choice are tools for the development of simulated production processes for the areas of ergonomics and process time. They help to ensure an optimal user experience and a safe production environment.
The experts at EDAG Group have built up extensive expertise in the digitalization and simulation of industrial production - both for systems and processes. They use an extensive portfolio of software applications for this purpose. For the simulation of manual processes in production, for example, relies on emaWD from the Chemnitz-based provider imk Industrial Intelligence.
The software is used for holistic workplace and process design. To this end, the working environment and workpieces to be processed are converted into digital representatives and the entire manual process is modeled in its individual work steps. In this way, manual activities and human-robot system sequences can be visualized and complete manufacturing and assembly processes can be simulated in 3D in order to check them for ergonomics and safeguard all processes.
Efficient data acquisition
However, recording the necessary data can be very time-consuming, such as the dimensions and position of all objects in the work environment - be it shelves, storage containers, work surfaces or tools, as well as information on the various movement sequences. The emaWD therefore has an Excel import interface as well as a standardized multi-page Excel document template, the "ema Wizard", which simplifies data acquisition to a certain extent.
Data import using the ema Wizard reduces the effort required to prepare the process simulation.
But that's not all: The ema Wizard can be filled using the programmed script , so that structured data can be automatically transferred, for example from Excel lists or from 3D planning tools, such as the CAD systems from Bentley Systems (MicroStation), Dassault Systèms (Delmia, Catia V5) or Autodesk (Inventor). At EDAG, corresponding scripts are created to suit the respective application, whereby manual data input is also simplified by an intuitive mask requesting the required information, as can be seen in the following illustration:
Input mask for the accelerated simulation setup
And this is how the example shown works:
(1) A new file is created based on the basic information entered here.
(2) The individual input fields of the stations are only enabled for the number of stations that are to be taken into account within the simulation.
(3) The customer's details can also be entered in this area.
(4) In the middle field for each activated station, a number of workers between 0 and 9, a selection as to whether a robot is present within the station and the name of the respective station are specified. The station name is used to create a link to the logistics and layout files.
(5) The optional folders are structural elements that are not used in every project.
(6) The selection regarding the "Logistics / Facilities" can then be made once via the general selection of the individual components and, in the case of pallets, additionally via an indication of the number.
(7) Finally, the number of levels and KLTs per level must be specified. However, the program has a default setting that covers most projects and racks.
After confirmation, the entries are automatically converted to the required Excel format and can be imported via the wizard in emaWD. Further information from the areas of logistics, layout and process is provided beforehand via separate Excel lists, as well as component data and additional standard component data in a special geometry folder.
Meaningful results
Manual production processes can then be realistically simulated on the basis of this data. The findings from the virtual production process bear fruit in a variety of ways. For example, potential for greater efficiency and ergonomics can be discovered and leveraged in early concept planning and subsequent detailed planning, such as possible bottlenecks, long distances for workers or their underutilization. The automatically generated ergonomics assessments comply with the NIOSH and EAWS standards, and risk areas in accordance with DIN EN ISO 13851 are also displayed visually so that the workplace design can be quickly optimized.
The application can be used to validate and safeguard manual, automated and robot-supported processes. The emaWD also determines the cycle time of a defined process according to the MTM-UAS method, which is crucial for evaluating the effectiveness of a production line
The data collected and results obtained can also be used in other tools and applications, for example to optimize user guidance, monitor and adapt operating processes, enable virtual training or develop AR/VR applications (augmented/virtual reality). The application is thus embedded in an increasingly digital development and operating environment in which all structures, processes and dependencies are viewed holistically. 
Planning process based on a digital tool landscape
Conclusion
The benefits of digital planning are undisputed. It offers time savings through shorter planning times, cost efficiency through optimized processes and better use of resources, improved accuracy and reliability of planning and forecasts, transparency and traceability of decisions and, last but not least, greater flexibility, as digital planning enables faster adaptation to changing requirements.
This makes it all the more important to utilize these advantages not only in the environment of machines and robots, but also in the deployment of workers. With the use of suitable tools and the necessary know-how, the effort involved remains manageable.
Are you also involved in the simulation of manual processes in production or are you looking for suggestions on how to increase efficiency potential in this area? Then talk to our expert Philipp Hummel, Senior Manufacturing Engineer at EDAG PS. Or download our white paper "Digital production and logistics planning as the key to future-proof production". Here you will find information on emaWD and other software tools and how they help to optimize factory processes and keep them flexible and scalable in the future. 
