Ford Rouge Factory Tour

WEAR & CARE

Can exoskeleton devices improve operator ergonomics on the vehicle assembly line?

ONE OF THE FORD ROUGE FACTORY

TOUR’S favorite attractions is the walking tour of the Dearborn Truck Plant, where the Ford F-150 is built. An elevated walkway spanning a third of a mile provides a bird’seye view of the plant’s final assembly line, where you see firsthand the complex web of equipment and skilled operators that comes together to build one truck every 53 seconds.

Tourgoers with an extra-keen eye may also notice some of these operators sporting outside-the-box workwear accessories. Since 2016, Ford Motor Co. has been studying the feasibility of exoskeleton devices, asking workers in final assembly at Dearborn Truck Plant and several other plants across the United States to voluntarily wear an arm-support exoskeleton so ergonomics engineers can collect data about its potential protective properties.

The adjustable, lightweight EksoVest used in the studies provides mechanical arm support to workers as they perform overhead tasks — many performing such motions on the job roughly 1 million times per year.

“Our whole goal from the start has been to strategize on how to reduce the number of shoulder injuries — they are tricky joints,” said Marty Smets, Ford ergonomics engineer and a lead on the exoskeleton studies. “No matter how strong you are, shoulder muscles are some of the weakest in your body. For a purely protective purpose, we wanted to better understand how exoskeletons may act to increase the fatigue resistance of the shoulder and reduce muscle discomfort and injury risk for the operator.”

In collaboration with Virginia Tech and in partnership with the UAW, Ford has completed an 18-month usability field study with the EksoVest. “The long-term value of this technology has not been systematically explored in the field, and lab studies don’t tell the complete story,” said Smets, who helped conduct the latest study in eight assembly plants with user and control groups at each location. “We wanted to know if an armsupport exoskeleton could actually improve workers’ comfort and risk of injury.”

The study results, said Smets, make him cautiously optimistic about increasing accessibility to this technology in the assembly plant as a way to improve worker comfort and mitigate work-related shoulder injuries. “We asked a lot of usability questions about overall comfort, fit, intent to use, perception of safety and job performance, and made some interesting findings,” he said.

At the conclusion of the study, 62% of the volunteers said they would continue to wear the EksoVest, claiming it improved their overall comfort and job performance. In addition, those wearing the device (versus the control group) were 52% less likely to make a visit to medical services.

“There’s a huge opportunity for exoskeleton technology moving forward,” said Smets, who will soon publish additional papers on Ford’s research with exoskeletons. “This is the first time anyone has produced evidence in the field that suggests an exoskeleton could be a promising intervention to reduce workrelated shoulder injuries.”

— JENNIFER LAFORCE

ONLINE For the most up-to-date information, hours and pricing for the Ford Rouge Factory Tour, visit thf.org/rougec ONLINE See the EksoVest in action, worn by assembly line operators at Ford plants across the country during a recent usability studyc

FUNCTION NOT FASHION

Exoskeleton devices could become familiar workwear necessities on assembly lines of the future. At the height of the Ford Model T, the dawn of the assembly line and Henry Ford’s $5 Day excitement, however, it was blue denim bib overalls that were often the workwear item of choice for those working in factories or fields. If not overalls, maybe denim jeans with a denim or chambray shirt. In the winter, you’d see more cotton or wool flannel shirts. Seams were triple stitched, and stress points on overalls and jeans were reinforced with copper rivets. Everything was fullcut for ease of movement. Leather lace-up boots that went just above the ankles would’ve been most common, and aprons would’ve been worn for particularly messy jobs — like those involving paint, lubricants, etc.

As a rule, function was more important than fashion in all articles of work clothing in the early 20th century.

— MATT ANDERSON, CURATOR

OF TRANSPORTATION

dModel T dashboard assembly at Ford Motor Company

Highland Park Plant, circa 1918

FROM THE HENRY FORD ARCHIVE OF AMERICAN INNOVATION

bFord Motor Company has been studying the feasibility of exoskeleton devices like the one shown here since 2016. More than 60% of workers in final assembly at Dearborn Truck Plant and several other Ford facilities, who recently participated in an 18-month usability study, said they would continue to wear the device, claiming it improved comfort and job performance.

PHOTO COURTESY OF FORD MOTOR CO.