Human factors and ergonomics

The paradigm of Industry 5.0 pushes the transition from the traditional to a novel, smart, digital, and connected industry, where well-being is key to enhance productivity, optimize man–machine interaction and guarantee workers' safety. This work aims to conduct a systematic review of current methodologies for monitoring and analyzing physical and cognitive ergonomics. Three research questions are addressed: (1) which technologies are used to assess the physical and cognitive well-being of workers in the workplace, (2) how the acquired data are processed, and (3) what purpose this well-being is evaluated for. This way, individual factors within the holistic assessment of worker well-being are highlighted, and information is provided synthetically. The analysis was conducted following the PRISMA 2020 statement guidelines. From the sixty-five articles collected, the most adopted (1) technological solutions, (2) parameters, and (3) data analysis and processing were identified. Wearable inertial measurement units and RGB-D cameras are the most prevalent devices used for physical monitoring; in the cognitive ergonomics, and cardiac activity is the most adopted physiological parameter. Furthermore, insights on practical issues and future developments are provided. Future research should focus on developing multi-modal systems that combine these aspects with particular emphasis on their practical application in real industrial settings.

Keywords: cognitive ergonomics , human–machine interaction , human–robot interaction , industry 5.0 , physical ergonomics , workplace well-being

[No abstract available]

Keywords: affective computing , affective elicitation , augmented/virtual reality , biometrics , emotion assessment , human-computer interaction , neuroscience , physiological data

The central role that the human operator assumed in industrial design and development processes, driven by Industry 5.0 principles, has paved the way for the creation of new human-centric system architectures. This paper discusses the practical implications regarding the deployment of a Human Digital Twin-based system in the manufacturing environment. It provides a proof-of-concept of the architecture for the implementation of the twinning process, starting from the investigation of the most suitable hardware selection based on the desired outcomes to build up the human monitoring phase. We analyze three management decision-making levels to determine the scalability of the proposed architecture for strategical, technical, and operational managerial strategies. This research aims to propose some technological selection criteria, based on the main characteristics of the available technological acquisition devices, to determine the most suitable sensors for the creation of the physical twinning monitoring process.

Keywords: Digital Twin , HDT Architecture , Human-centered design , Industry 5.0 , Operator 4.0

The polishing of luxury leather shoes is a delicate, labor-intensive process traditionally performed by skilled craftsmen. Footwear companies aim to automate parts of this process to enhance quality, productivity and operator well-being, but the unique nature of luxury shoe production presents challenges. This paper introduces a solution involving a collaborative robotic cell to assist in shoe polishing. A collaborative robotic manipulator, equipped with a specialized tool and governed by force control, executes the polishing tasks. Key factors such as trajectory design, applied force, polishing speed and polish amount were analyzed. Polishing trajectories are designed using CAM software and transferred to the robot's control system. Human operators design the process, supervise the robot and perform final finishing, ensuring their expertise is integral to achieving quality. Extensive testing on various shoe models showed significant improvements in quality and reliability, leading to successful implementation on an industrial production line.

Keywords: collaborative robotics , human computer interaction , human robot collaboration , human-centred manufacturing , Shoe polishing

In recent years, exoskeletons have gained the attention of researchers and industry. Their use can improve the quality of life of operators by reducing musculoskeletal accidents. Evaluating the usability and transparency of exoskeletons requires consideration of objective metrics such as physiological parameters, biomechanics of movement and muscle activation, as well as subjective parameters. Large-scale field research plays a crucial role in identifying and monitoring potential effects related to the use of exoskeletons in a real-world environment. In addition, these studies can help establish a thorough scientific basis to support the refinement of ergonomic risk assessment methods, safety standards, regulations, and the formulation of guidelines and best practices for the selection and use of exoskeletons. The review includes several articles dealing with exoskeletons for shoulder and back support both in the laboratory and in the field. The state-of-the-art study shows the methodologies for testing the effectiveness of exoskeletons, highlighting the differences between tests conducted in the laboratory and in the field. In addition, the authors' methodological proposal is presented, illustrating a specific case being developed for the project 'Innovation, digitization and sustainability for the diffuse economy of Central Italy - VITALITY'.

Keywords: electromyography , exoskeleton , field studies , laboratory studies , motion tracking system , sensors

The design of modern production systems is requiring more and more integration of human-in-the-loop principles introduction of new working paradigms, where humans and machines cooperate and interact with each other. Such practices are reinforcing the need for human-centric smart manufacturing (HSM). Today, human-cyber-physical systems (HCPSs) allow to intrinsically meet the industrial complexity and bring insights in the development and implementation of HSM. In this context, the growing interest of academics and practitioners on the three key concepts of “sustainability, human-centric, and resiliency” related to the Industry 5.0 (I5.0) framework is justified. The aim of this study is to present a methodological approach for the design of adaptive human-cyber-physical systems to meet the I5.0 objectives. Starting from the analysis of the as-is user and process-related conditions, this innovative closed-loop framework guarantees a step-by-step tuning logic according to specified objectives. A use case concerning a quality control procedure for the Oil&Gas sector is proposed, where a preliminary HCPS prototype has been developed and tested. The solution provides a contextual support throughout all the value chain to the diverse activities carried out by design engineers up to end-users by offering a valuable operator's user experience (UX). The main results suggested that the conceived strategy overcomes traditional limitations of the technical drawings by integrating model-based engineering with human-centred design (HCD) principles. The systematic introduction of HCPS allows to redesign the human–machine interaction according to new paradigms of collaboration between the humans and the smart factory.

Keywords: Augmented reality , Human-cyber-physical system , Human-in-the-loop , Human-machine interaction , Industry 5.0

[No abstract available]

Featured Application: This paper proposes a protocol for researchers, ergonomists, and industrial practitioners to design and carry out well-structured experiments that allow for reliable and valid comparisons between different exoskeleton designs or configurations, considering factors such as user characteristics, task demands, environmental conditions, and subjective user perceptions. This paper proposes a modular protocol for the designing of experimental studies to analyze exoskeletons used in industrial settings to support manual material handling (MMH). Despite exoskeleton technologies starting to be highly commercialized and present in workplaces, research still lacks a standardized procedure for analyzing the impact of these devices on workers. The protocol presented in this paper outlines a step-by-step procedure, including the parameters to be collected and analyzed in a research study. Moreover, the approach could be easily adapted to meet the specificity of a wide range of exoskeletons. The main novelty of the protocol is thus to support the experimental design and analysis of studies assessing the overall impact of exoskeletons on workers. To implement the protocol, the selected case study concerned a palletizing task involving the MMH of 12 cardboard boxes, weighing 10 kg. The results from physiological signals and pressure insoles show that the protocol is comprehensive and can be utilized by researchers evaluating different occupational exoskeletons for assistance during MMH (both active and passive), with modifications to specific parts based on the type of exoskeleton being assessed or the variables of interest.

Keywords: experimental study , manual material handling , occupational exoskeleton , protocol

The advent of Industry 4.0 has led to the need to train highly skilled operators in complex and dynamic environments, through the convergence of physical and digital technologies. In this context, indoor navigation plays a crucial role in the training of Operators 4.0, allowing them to acquire spatial knowledge and specific skills to operate effectively in advanced industrial environments. However, the challenges associated with this technology, such as environmental complexity and obstacles, require an innovative approach to operator training. Mixed Reality (MR) represents a promising technological innovation for the development of these systems. Indeed, MR enables the co-represence of digital and real world, by content overlapping and integrated interaction between virtual and real assets, promoting efficiency, safety and user engagement. Within this scenario, the paper proposes a Holographic Navigation (HoloNav) methodology based on spatial and cloud computing for the development of an indoor navigation application according to a transdisciplinary approach. The application is deployed on the Microsoft HoloLens 2 as MR device, using Microsoft Azure Spatial Anchors (ASA) and Cloud Storage Account resources. This study aims to provide an applied methodology and guidelines for application development, and to analyze the broader social implications and potential for social change of such MR technology to support training processes. The proposed ASA-based HoloNav approach was applied through a case study, where a tour inside the spare parts warehouse was developed for new operators who need to start familiarizing themselves with all the different areas.

Keywords: Indoor navigation , Microsoft HoloLens 2 , Mixed reality , Transdisciplinary engineering , User experience

The term Human-Centric Digital Twin (HCDT) has been recently coined meaning the design and the simulation of complex production systems by integrating human factors. This paper presents an HCDT system architecture focused on an enhanced 3D virtual model, embedding human interaction information in product and process information. Such a model extends the current features of AutomationML (AML) framework, a recently defined standard for digitization in Industry 4.0, by specific human-related data. The framework has been primarily integrated into a Virtual Reality (VR) scenario to support, predict and study the human-system interactions in the early stages of industrial machine design. The infrastructure has been validated on a real case developed in collaboration with an Italian manufacturing company, world leader in automatic machine design and production. User testing was conducted within a virtual environment, where the HCDT enriched the 3D virtual model of the machine with an additional AML description of human-system interaction.

Keywords: AutomationML , Digital Twin , Human-Centric Digital Twin , Human-machine interaction , Industry 5.0

The use of Extended Reality (XR) technologies virtual and augmented reality (AR) is establishing itself more and more in design, construction and operation applications in industrial and research sectors that aim to employ digital technologies with a human-centered design approach. At ITER, a methodology that includes these technologies is applied in the design study of test blanket module (TBM) port cell (PC) components and replacement operation. The use of virtual prototyping at early design phases permits anticipating issues related to human operation and accessibility. Therefore, design optimization is performed before manufacturing the actual feasibility mock-ups. XR sessions are organized involving several design experts interacting with the various components 3-D models at the same time to facilitate the design decisions and to optimize the procedures. The main asset of this XR approach is to offer different means to support the decisions and onboard all participants. The simulations are prepared by building a virtual mock-up based on native CAD models available in databases for the different systems integrated into the Tokamak building. The complexity of the systems and the large amount of data to display require data preprocessing in order to ensure a reliable representation of the scenarios to be simulated. The reliability of the 3-D data and the consideration of the risks and the environmental conditions of the areas to be simulated are essential for making applicable and sound decisions. The aim of this article is to provide a method to realize reliable XR simulations following a documented workflow usable across the ITER project. The method is based on the realization of an XR-maintenance verification plan as an input for the XR simulation and of a maintainability verification document based on the results available from XR simulations. The experience and the results gained from the TBM PC design activities involving virtual reality (VR) simulations are also discussed.

Keywords: As low as reasonably achievable (ALARA) , early design validation , extended reality (XR) , maintenance , test blanket modules (TBMs) , virtual reality (VR)

In recent years, operator ergonomics has been playing an important role, driven by workplace regulations and worker safety in manufacturing settings characterized by physical demands and injury risks. Traditional ergonomic evaluation methods rely mainly on observation and manual measurements, which are subjective, reactive, and sometimes challenging to perform. Technologies, such as virtual reality devices and motion capture systems, offer opportunities to streamline data collection and enhance objectivity. Moreover, Industry 4.0 introduced digital twins, facilitating ergonomic evaluations in virtual environments. This paper presents a framework that integrates Virtual Reality technologies and motion capture analysis to support ergonomists in evaluating operators' working conditions in manufacturing settings. The operator wears a head mounted display to simulate working tasks in a virtual replica of the real plant. An inertial motion capture system is employed to automate data gathering and processing for an objective evaluation of the operator's postural condition. A Virtual Wall system is exploited by the ergonomist for the evaluation of the tasks using the motion captured data. A case study has been considered to test the functionality of the platform. A tester repeats a sequence of tasks both in real and virtual scenarios in order to compare the results. Ergonomics is evaluated through three standard indexes (i.e., RULA, REBA, OWAS), resulting in a strong correlation between data acquired interacting with physical and virtual environments.

Keywords: Digital Twin , Ergonomics , Semi-immersive Environment , Simulation

Construction machines, for example cranes, excavators, or bulldozers, are widely diffused systems operating outdoors in harsh and dangerous environments, such as building sites, forests, and mines. Typically, construction machines require the on-site presence of highly skilled users to manage the complexity of their control and the high power of hydraulic actuation. Construction machines could benefit from recent developments of robot avatar technology that has demonstrated the viability of remotizing human physical activities, leveraging on intuitive interfaces and controls. Similar approaches could also improve the overall usability of construction machines, making them safer and accessible for untrained users. With this in mind, we developed a novel system for the remote control of cranes through intuitive and immersive interfaces. To validate the solution, we evaluated the experience of approximately 80 untrained users that remotely operated a crane during the 33rd Edition of Bauma, the world's leading fair for construction machines.

Keywords: construction robotics , hydraulic systems , intuitive interfaces , remote control , usability

Despite the existence of numerous innovative solutions aimed at enhancing the objectivity and efficiency of physical ergonomics analysis, traditional methods are still widely used among ergonomists, relying on direct observation of workers and their task performances. This research addresses this gap by introducing AR4Ergo, an Augmented Reality platform specifically designed to assist ergonomists by computing real-time standard indexes and simulating musculoskeletal loads using biomechanical virtual models. Xsens inertial motion capture system is employed to monitor human movements, while the OpenSim Application Programming Interface has been integrated into AR4Ergo for the simulation of musculoskeletal loads. Microsoft Hololens v2 is used to visualize human and workplace digital twins with information relative to ergonomic indexes and biomechanical simulations during the observation of the tasks performed by workers. A test was conducted to evaluate the functionalities of the platform, with three testers taking turns performing the roles of both the ergonomists and the operators. The results demonstrate how real-time analysis with a visual interface can be performed to augment ergonomists' experience without modifying the basic observational procedure. Even if the feedback is positive, some improvements have been identified in order to allow the ergonomist to use AR4Ergo in daily practice for different industrial applications.

Keywords: Augmented Reality , Biomechanical Simulation , Ergonomics , Microsoft Hololens , Xsens

Motorsports is the most watched sport in the world and has millions of television viewers. Despite having this media coverage, the figure of the driver has been recognized as an athlete in the last decade. It was realized that in order to achieve better performance, in addition to the engineering and mechanical part, the rider's physical condition must also be improved. The rider's body is subjected to many forces during racing. It will be explored in depth how these aspects can negatively affect the body and how to counteract their negative effects with both preventive and compensatory exercises specifically designed.

Keywords: biomechanical assessment , Motorsport , preventive exercises

In this paper we define an optimized digital twin knowledge network based both on the carrying capacity and preferential attachment. It is a logistic growth scale-free network which solves a min-max problem. The main advantage of this model is to build an integrated system (humans-digital twins) aiming to the max efficiency with limited costs of management.

Keywords: Digital Twin , Human-machine interaction , Industry 4.0 , knowledge graph , networks , smart manufacturing

Writing is first-order instrumental learning that develops throughout the life cycle, a complex process evolving from early childhood education. The identification of risk predictors of dysgraphia at age 5 has the potential to significantly reduce the impact of graphomotor difficulties in early primary school, which affects handwriting performance to such an extent that it can become illegible. Building on established scientific literature, this study focuses on screening processes, with particular attention to writing requirements. This paper proposes a novel prevention and intervention system based on new technologies for teachers and educators or therapists. Specifically, it presents a pilot study testing an innovative tactile device to analyze graphomotor performance and motor coordination in real time. The research explores whether this haptic device can be used as an effective pedagogical aid for preventing graphomotor issues in children aged 5 to 6 years. The results showed a high level of engagement and usability among young participants.

Keywords: decision support system , dysgraphia , dysgraphia early identification , dysgraphia risk predictors , graphomotor skills , handwriting , haptic training , specific learning disorders

With the expansion of the Internet and mobile services, digital exclusion due to accessibility barriers remains a concern, particularly in understanding complex web content. This study investigates the application of Large Language Models (LLMs) like OpenAI's ChatGPT for simplifying sentences in line with easy-to-read (E2R) guidelines. Through two exploratory studies, we assess LLMs' awareness of E2R guidelines and their capability to simplify sentences to enhance cognitive accessibility in an archaeological museum context. The first one aims to assess LLMs' general knowledge about E2R guidelines. The second one evaluates their ability to perform SS conforming to E2R guidelines in order to generate accessible textual information for an archaeological museum. To this end, results of SS provided by LLMs are compared with text made by students who attended training on the E2R guidelines and those made through a co-design process with people with cognitive disabilities.

Keywords: Cognitive accessibility , Easy to Read , Large Language Models , Sentence Simplification

No abstract available

This paper presents a pioneering pilot study conducted at ARGOR-HERAEUS SA, focusing on integrating Augmented Reality (AR) HoloLens technology for emergency training and management in the scrubber System. The scrubber system, known for its relevance in terms of reducing pollutants and thus its potential dangers in case of malfunction, poses unique challenges for emergency preparedness and response. The study utilizes Unity3D to develop immersive training scenarios and emergency situations, enhancing trainee preparedness.

Keywords: ARGOR-HERAEUS SA , Augmented Reality , Emergency Management , Emergency Training , HoloLens , Pilot Study , Scrubber System , System Usability Scale (SUS) , Unity3D