Leveraging Exoskeletons to Reduce Musculoskeletal Disorders in Aluminum Forging: A Case Study

Abstract

Musculoskeletal disorders (MSDs) are a long-term challenge in Germany, leading to significant sick leave and financial losses across industries. To address these issues, a German automotive supplier specializing in aluminum forging and cold forming initiated a pilot project to explore the potential of exoskeleton technology. The project, conducted in collaboration with exoIQ GmbH, a Hamburg-based start-up specializing in intelligent support systems, aimed to improve employee health, alleviate workplace strain, and enhance overall working conditions.The necessity for this intervention was underscored by findings from a company-wide survey conducted in collaboration with a health insurance provider. This survey revealed high levels of sick leave attributed to MSDs, confirming the need for immediate ergonomic solutions. Additionally, the Key Indicator Method (Leitmerkmalmethode) was employed to evaluate ergonomic risks at selected workstations. This method, used as both an assessment and benchmarking tool, identified critical tasks with significant biomechanical strain, providing a foundation for targeted interventions.To address these challenges, three exoskeletons designed by exoIQ GmbH were integrated into the production environment for a four-week trial. The devices were selected for their ability to reduce strain in physically demanding tasks and were tested under realistic working conditions. Employees with diverse body types and physical profiles participated in the study, ensuring a comprehensive evaluation of the technology’s adaptability and eTectiveness.The trial incorporated multiple methods to assess the impact of the exoskeletons. Observational data and ergonomic assessments were gathered alongside employee feedback collected through structured interviews and surveys. The Key Indicator Method was applied to compare risk levels before and after exoskeleton implementation. Quantitative data included metrics such as muscle activation, joint stress, and task completion times, while qualitative data captured user experiences, including perceived comfort, ease of use, and mobility challenges.Preliminary findings demonstrated a marked reduction in physical strain, particularly for tasks involving overhead work, heavy lifting, and repetitive motions. Ergonomic risk assessments indicated notable improvements, with reductions in key strain markers. Employees reported lower levels of fatigue, greater task eTiciency, and improved well- being while using the exoskeletons. However, some limitations, such as the weight and mobility of the devices, were identified, suggesting areas for future refinement.This case study highlights the potential of exoskeleton technology as an eTective ergonomic intervention in high-strain industrial environments. By combining innovative technology with robust evaluation methods, including health insurance data, the Key Indicator Method, and direct user feedback, this approach provides a replicable model for industries seeking to reduce MSD-related sick leave and improve workplace conditions.The findings also emphasize the importance of involving employees in the evaluation process to identify practical challenges and opportunities for optimization. Lessons learned from this pilot project will inform future research and the development of tailored exoskeleton solutions for diverse industrial applications.

Keywords: Assistive Technology, Wearable Computing, Accessibility

DOI: 10.54941/ahfe1006016