Ergonomic Human Simulation Study: Design for Assembly of Dashboard in Vehicle

Efficient, safe, and worker-friendly automotive assembly processes are critical in today’s manufacturing industry. On the shop floor where vehicle dashboards are installed, operators must navigate through confined spaces, handle bulky components, and coordinate precisely with upstream and downstream tasks. Assembly of dashboards often requires technicians to work within tight ergonomic zones, repetitively reach across complex fixture setups, and adapt to varying vehicle models, all while maintaining speed and quality. Hinduja Tech’s expert application of human simulation and ergonomic analysis sets a benchmark for these outcomes.

Why Ergonomics and Human Simulation Matter?

Ergonomics and human simulation are crucial for modern manufacturing because they help design the work environment around the worker, rather than forcing the worker to adapt to a predesigned system. This human-centric approach yields significant benefits in terms of safety, productivity, and cost optimisation. Ergonomics minimizes strain and injury while driving operational efficiency by aligning tasks with human capabilities.

As production complexity increases, ensuring that each assembly task is ergonomically sound becomes vital for driving productivity, improving safety, and reducing costs. On the shop floor, ergonomic challenges can include awkward body postures, sustained overhead reaches, and the manipulation of heavy dashboard modules. When these factors are unmanaged, they increase the risk of fatigue and musculoskeletal disorders, resulting in inefficiencies and operational disruptions. Forward-looking manufacturers leverage virtual simulation not only to validate designs, but also to safeguard their workforce and bottom line.

Hinduja Tech’s Approach: Digital Simulation for Real Results

Hinduja Tech employs advanced digital manufacturing tools and domain expertise to optimize assembly processes for global OEMs. Using virtual human modeling, they simulate real-world movements and posture during dashboard installation, identifying risk points and optimizing workstation layouts. This simulation-driven approach provides actionable insights long before physical implementation, avoiding costly iterations and ensuring each process step meets global ergonomic standards.

Our expert teams leverage

• Digital human modeling software (Posture, reach, force, visibility, and fatigue analysis)
• Task simulation and process optimization
• Anthropometric data to tailor workflows for diverse operators
• Automated reporting aligned with regulatory and industry benchmarks

Case Study: Dashboard Sub-Assembly Analysis

In a recent dashboard sub-assembly project, Hinduja Tech collaborated with a leading manufacturer to address key ergonomic challenges:

• Manual installation tasks with complex reach and access zones
• Variability in operators' physical profiles
• Balancing cycle time with safe, repeatable movements
• Need for rapid feedback on workstation layout redesigns

Applying simulation expertise, Hinduja Tech

• Modeled tasks using digital human avatars representing multiple percentiles and postures
• Ran ergonomic risk assessments on critical motions, force application, and reach analysis
• Provided recommendations to adjust assembly sequence, optimize part orientation, and redesign workstation geometry to reduce risks
• Delivered actionable 3D work instructions that improved operator training and process efficiency

Measurable Business Impact

The results were immediate and quantifiable:

• 10% reduction in ergonomic risk scores across dashboard installation steps
• Cut cycle time on key tasks, improving overall workstation throughput
• Enhanced operator safety and comfort, reducing long-term injury potential
• Clear digital documentation for ongoing process improvement and compliance

Manufacturers benefited from fewer work-related injuries, improved productivity, and significant reductions in downtime and associated costs.

Why Hinduja Tech?

With years of automotive manufacturing expertise and cutting-edge simulation capabilities, Hinduja Tech delivers scalable ergonomic solutions tailored to complex production environments. Serving over 100 global OEMs and Tier-1s, our multidisciplinary teams specialize in:

• Process simulation and digital validation
• Ergonomic workstation and line design
• End-to-end engineering support, from design through execution

Hinduja Tech partners with clients to advance both operator well-being and sustainable manufacturing performance.

Partner with Hinduja Tech for Ergonomic Excellence

Ergonomic risks in assembly lines can be mitigated before they become costly realities. By integrating human simulation into process design, automotive companies can protect workers and unlock new productivity gains.

Learn how Hinduja Tech’s ergonomic analysis and human simulation services can empower your next program.

Contact us today at info@hindujatech.com