Digital Human Modelling Ergonomics
Design Smarter. Reduce Risk. Accelerate Innovation.
Bring virtual people into your design and safety process. Morgan Maxwell’s Digital Human Modelling (DHM) service uses ergonomic human models to simulate real work, revealing risks and opportunities long before you commit to physical prototypes.
We use Process Simulate Human, powered by Siemens’ Jack technology, to model, analyse, and optimise how people interact with your products, tools, and environments—at concept, during development, and pre-deployment.
Available as a consultancy engagement or bundled with selected Industrial Ergonomics AI software subscriptions for a seamless mix of software, human factors simulation, and chartered ergonomist expertise.
Let us show you how Digital Human Modelling and our Industrial Ergonomics AI software can work together for your business.
WHY DIGITAL HUMAN MODELING MATTERS?
Design decisions made early are the cheapest to change. But most teams still rely on assumptions about reach, access, posture, visibility and handling effort until a prototype, pilot build or ramp-up reveals problems.
Digital human modelling in ergonomics brings virtual people into your design process so you can:
- Identify ergonomic risk and task failure points early
- Reduce rework, late design changes and retrofit cost
- Support compliance and due diligence with traceable evidence
- Improve usability, maintainability and overall performance
Morgan Maxwell delivers DHM as a practical, engineering-friendly service with outputs that support industrial ergonomics design reviews, stakeholder buy-in and implementation.
WHAT IS DIGITAL HUMAN MODELLING IN ERGONOMICS?
Digital human modelling can be used alongside a ergonomics risk assessment & creates an ergonomic human model (a parameterised “digital human model”) that represents different body sizes and capabilities (e.g., 5th–95th percentile). We use these models to evaluate work and product interaction inside CAD, including:
- Reachability and clearance
- Posture and joint loading indicators
- Line of sight and visibility
- Handling feasibility and task effort
- Collision, pinch and entrapment checks
- Fatigue and time-at-risk indicators (where applicable)
This replaces guesswork with visual, evidence-based human factors insight and can be used alongside ergonomics analysis software.
Typical use cases
Workstation and line design:
Layout, heights, access, tooling, fixtures, changeovers and space constraints.
Manual handling & assembly:
Lift/carry/push/pull feasibility, insertion forces, part presentation and reach zones
Product usability & serviceability:
Controls, displays, hand clearance, maintenance access and service postures.
Human factors in simulation and training:
Validate procedure steps, detect “error traps” and produce accurate task visualisations for training assets.
Inclusive design:
Design for a wider user population—PPE constraints, restricted mobility scenarios or specialist user groups.
Learn more on Digital Human Modelling
How Our DHM Service Works
- Discovery & Scope We align on tasks, scenarios, user population, performance targets and any relevant standards/guidance.
- Data & Model Setup You provide CAD (e.g., STEP/JT/IGES/Parasolid) plus task details. We configure the digital human model to match your workforce needs (percentiles, PPE, restrictions).
- Human Factors Simulation We simulate tasks and evaluate reach, clearance, visibility, posture and feasibility—highlighting where designs create strain, access issues or unsafe workarounds.
- Compare options and optimise We quantify risk differences, compare alternatives and iterate design concepts—showing before/after impacts for safety, quality and takt.
- Deliverables and handover You receive clear outputs for design reviews and implementation, with optional coaching for engineering and project teams.
WHY MORGAN MAXWELL
Chartered ergonomics expertise
DHM is delivered by CIEHF-registered Chartered Ergonomists, producing evidence you can rely on in design reviews and audits.
Practical, engineering-friendly outputs
Clear visuals and actionable recommendations—built for decision-making, not academic reports.
Integrated support available
Where helpful, DHM can sit alongside industrial ergonomics assessments, training and software-enabled tracking.
What You Get (Deliverables)
You receive a DHM deliverables pack typically including:
- Executive summary of key ergonomic risks and recommendations
- Annotated screenshots, visuals and posture evidence (heat-maps where appropriate)
- Short simulation media (e.g., MP4 walkthroughs) to support stakeholder buy-in
- Standards-aligned rationale and implementation guidance
Where DHM Adds the Most Value
- new line/cell introductions and layout changes
- Automation and human collaboration (including cobots)
- Tight-tolerance assembly or difficult service access
- High-mix/low-volume environments with many variants
- Regulated sectors requiring traceable human factors evidenc
Some of our clients
