Feasibility study of exoskeleton integration for manual material handling tasks at HORSE Powertrain

Sammanfattning

Work-related Musculoskeletal Disorders (WMSDs) represent a major challenge in industrial Manual Material Handling (MMH) operations, particularly in the automotive sector. This degree project was carried out in collaboration with HORSE Powertrain in Skövde (Sweden) in response to the company’s need to replace its ageing picking-truck system with a more cost-efficient and ergonomically sustainable solution. Since the current logistics transition from the company towards Auto-Guided Vehicles-supported (AGV) material flow has increased the amount of manual handling required from operators, HORSE expressed interest in evaluating whether industrial exoskeletons could compensate for the loss of mechanical assistance while maintaining operational efficiency and reducing physical strain on workers. The study combines the Double Diamond methodology with Design Science Research (DSR) principles. Fieldwork at HORSE included direct observation of workers, task decomposition, video-based Motion Capture (MoCap), ergonomics analysis, and workflow evaluation. Digital Human Modeling (DHM), Computer Vision (CV) techniques, and ergonomics assessment methods such as Rapid Entire Body Assessment (REBA) and the Revised NIOSH Lifting Equation (RNLE, from the National Institute for Occupational Safety and Health) were used to analyse the biomechanical demands of the task. In parallel, a market analysis of industrial exoskeletons was conducted to compare different solutions regarding effectiveness, usability, mobility, maintenance requirements, and economic feasibility. The results indicate that exoskeletons can reduce biomechanical load and improve ergonomics conditions during repetitive lifting tasks. However, their suitability strongly depends on the operational context, task dynamics, worker mobility, and implementation costs. Passive exoskeletons were identified as the most viable option for HORSE’s logistics environment due to their lower complexity, reduced maintenance needs, and lower economic impact compared to active systems. The Apex 2 by HeroWear was selected as the most suitable solution. Its lightweight passive design, quick disengagement system, and short donning time make it well suited to HORSE's dynamic workflow, and its documented reduction in lower-back muscle activity directly addresses the main ergonomic risks identified. However, it should not be regarded as a standalone solution, as workstation design issues such as excessive trunk flexion caused by low shelves remain unresolved. The Laevo V2.6 is also a strong alternative depending on the company's priorities.