The employee pulls the exoskeleton from manufacturer Laevo over his head like a sweater and straps it to his hips. They then place two fist-sized plates on their thighs, which distribute the load accordingly. Positioned in this way, the exoskeleton supports the employee, particularly during activities that require the upper body to bend forward in order to pick up or put down components. Carrying heavy materials is also easier with this ergonomic design. This is because the exoskeleton directs the load of the lifted elements from the torso to the more pronounced thighs. This relieves the back muscles by 20 to 30 percent and at the same time promotes a healthy posture. The ergonomic design helps employees with their daily tasks without restricting their freedom of movement.

Thanks to the flexible structure, he can walk, turn and stretch as usual. "An ergonomic way of working is a high priority in all areas at Audi - including in the production and logistics areas. "With the exoskeleton or - as we also call it at Audi - the Ergoskeleton, we enable employees to work healthily, we avoid overloading them and maintain their performance," says logistics planner and head of the "Ergoskeleton" project Vinzent Rudtsch.

Employees at the Audi sites in Ingolstadt and Neckarsulm are currently testing the first industrial-grade devices for various tasks. In CKD (Completely Knocked Down) logistics, for example, the aid supports employees when they pick up components from boxes. In assembly, the exoskeleton makes it easier to install the center console or carry heavy material boxes, among other things. During the test phase, the usage time gradually increases from two hours a day to up to seven hours in a day shift. An interdisciplinary team of process and workplace planners as well as medical professionals are supporting the pilot project.

The tests are being carried out in collaboration with the Dutch manufacturer Laevo, which specializes in exoskeletons. The aim is to gradually integrate the aid into series production at all Audi sites worldwide after the test phase. cs