Using Digital and Physical Simulation to Focus on Human Factors and Ergonomics in Aviation Maintainability.

Objective: This research aimed to evaluate the differences in the assessments made by three simulation tools used in a maintainability design office to perform human factor/ergonomics (HFE) analysis: digital human modeling (DHM), virtual reality (VR), and physical mock-up (PMU).

Background: Maintainability engineers use digital/physical simulation tools in the early design phase to analyze whether the design is well adapted for maintenance operators. Knowing the potential of these simulation tools would encourage maintainability stakeholders to integrate HFE in the design process more efficiently.

Method: Eleven maintenance tasks were analyzed from the participation of six maintenance operators. Various HFE indicators including physical, cognitive, and organizational indicators were assessed. Each operator repeated 11 maintenance tasks on VR and PMU. Based on the anthropometric parameters, six manikins were created to analyze 11 maintenance tasks on DHM.

Results: A significant difference was found for the organizational indicators between VR and PMU, whereas the physical and cognitive indicators are similar. DHM, VR, and PMU are compared with the common HFE indicators for the physical dimension and present a significant difference for individual tasks.

Conclusion: To reduce the gap between simulation tools, a better physical representation is requested on the VR platform, improving the perception of work sequences in the virtual world. Concerning DHM, a new paradigm is proposed to study a few tasks per work area instead of studying each task independently.

Application: This study will help develop a new methodology and tools specifically for non-HFE experts in the maintainability department.