Virtual workplace design for the ability-based deployment of performance-challenged employees for Daimler Truck AG


The task in the project was to redesign and transfer several decentralized pre-assembly workplaces in axle production to a new, central production area at Daimler Truck AG. The primary objective was to investigate the integration of employees with reduced performance, so-called employees with limitations (ME), into the existing hall structure and to create a digital twin of seven workstations for planning purposes with the help of modern software.


In the first step, the current actual conditions including all necessary data were recorded in an on-site inspection. In addition to information on the required components (e.g. weights, material requirements and daily requirements), this also included the dimensions and functions of the devices used at the workstations. On this basis, the ema Work Designer software solution was then used to create an initial digital layout concept for mapping the necessary material supply, equipment and basic workplace dimensions, taking into account current guidelines.

The next step was the iterative detailing of the initial scenario according to the requirements of capability-oriented workplaces. This included not only the adaptation of the material flow (e.g. reduction of the load handling of KLT/GLT) but also the technical redesign of e.g. fixtures and manipulators. While ensuring ergonomically favorable work processes, the assembly volumes at the individual workplaces were then simulated and further potential for improvement was identified. The iterative optimization of the individual workstations was carried out in a continuous exchange of ideas, including workshops with planning, production and logistics on site.

Based on the coordinated solution as a digital simulation, technical specifications were created for each workstation. This was followed by the first assembly of the workstations in the prototype workshop.


The new central pre-assembly area enables the value-added integration of performance-transformed employees. The targeted design and continuous optimization of the workplace layouts, with the participatory involvement of all affected production and specialist departments, ensured acceptance of the solution concept presented. In addition to the ergonomic improvements, the redesign also identified and demonstrated potential with regard to production time and walking distances.

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