Working with California based exoskeleton maker Ekso Bionics, Ford has been piloting the use of a non-powered exoskeleton called EksoVest in two of their manufacturing plants in the U.S. The exoskeleton is designed to reduce fatigue from high-frequency activities.

Designed to fit workers from five feet to six feet four inches tall, the EksoVest adds 5 to 15 pounds of adjustable lift assistance to each arm. This exoskeleton is also comfortable enough to wear while providing free arm movement thanks to its lightweight construction.

The device is suited for real-world environments like factories, construction sites and distribution centers. The non-powered vest offers protection and support against fatigue and injury by reducing the stress and strain of high-frequency, long-duration activities that can take a toll on the body over time.

“Collaboratively working with Ford enabled us to test and refine early prototypes of the EksoVest based on insights directly from their production line workers,” Ekso Bionics co-founder and CTO Russ Angold said in a Ford press release. “The end result is a wearable tool that reduces the strain on a worker’s body, reducing the likelihood of injury, and helping them feel better at the end of the day – increasing both productivity and morale.”

Exoskeletons are already being used to help paraplegics walk, and applications for these technologies are even being expanded to provide support and enhancement for soldiers.

EksoVest is the latest example of advanced technology Ford is using to reduce the physical toll on employees during the vehicle assembly process. Between 2005 and 2016, the most recent full year of data, the company saw an 83 percent decrease in the number of incidents that resulted in days away, work restrictions or job transfers – to an all-time low of 1.55 incidents per 100 full-time North American employees.

To date, Ford ergonomists have worked on more than 100 new vehicle launches globally using ergonomic technology tools, including most recently the 2018 Ford Mustang, 2018 Ford F-150, and the all-new 2018 Ford Expedition and 2018 Lincoln Navigator.

Through significant investments in the program, not only has Ford achieved a reduction in employee incident rates, it has seen a 90 percent decrease in such ergonomic issues as overextended movements, difficult hand clearance and tasks involving hard-to-install parts.

“We refer to our assembly line employees as ‘industrial athletes’, due to the physical nature of the job,” said Allison Stephens, technical leader for assembly ergonomics at Ford. “We have made data-driven decisions through ergonomics testing that has led to safer vehicle production processes and resulted in greater protection for our employees.”