Ergonomic risk in manufacturing environments is often caused by repetitive movements and incorrect postures. Workers frequently perform the same actions for long periods of time, adopt non-neutral body positions, or remain standing throughout entire work shifts. Over time, these factors can lead to physical strain and contribute to the development of musculoskeletal disorders.
eXtended Reality (XR) offers a powerful approach to ergonomic training, as it allows workers to safely practice movements and postures in a controlled, risk-free environment. By simulating real work scenarios, XR makes it possible to repeat tasks multiple times, receive immediate feedback, and gradually build correct movement habits without exposing workers to physical risk.
The project EMPAIRED: Empathic AI and XR for Ergonomic Education aims to demonstrate the effectiveness of this approach by developing an XR-based ergonomic training experience for manufacturing. The training is enhanced by an empathic AI-powered avatar, Algho. Acting as a virtual coach and interacting through voice, Algho supports users throughout the training and enables the experience to be adapted to learners with diverse backgrounds and skill levels.
To evaluate the impact of XR-based ergonomic training in a realistic industrial context, CNC lathes with milling capabilities were selected as a representative case study. These machines are widely used across multiple manufacturing domains, including mechanical engineering workshops, automotive and mobility, and the energy industry, and are operated daily by hundreds of thousands of manufacturing workers worldwide.
Operating a CNC lathe exposes workers to several ergonomic risks, particularly during loading and unloading phases. These tasks often require prolonged standing, repetitive manual handling of workpieces, and sustained non-neutral postures involving the trunk, shoulders, and wrists to access the machine workspace and controls. When performed repeatedly over time, these actions can significantly increase physical strain and the likelihood of injury.
XR-based ergonomic training can help mitigate these risks by teaching correct body alignment, efficient movement strategies, and safe handling techniques tailored to the most physically demanding phases of machine operation. By allowing workers to practice these behaviors in immersive and realistic scenarios, XR training supports the development of safer habits that can be transferred to real-world tasks.
By combining immersive XR technology with an empathic AI-powered avatar, EMPAIRED explores a new way to address ergonomic risk in manufacturing.
Focusing on CNC lathe operations as a representative use case, the project highlights how adaptive, experience-based training can improve awareness, reduce physical strain, and support safer working practices. XR-based ergonomic education has the potential to become a valuable tool for enhancing worker well-being and promoting long-term sustainability in industrial environments.
EMPAIRED – Empathic AI and XR for Ergonomic Education is an ambitious, interdisciplinary project responding to the MASTER Project’s Panel 10 challenge on XR for remote and inclusive robotics education. Coordinated by the University of Siena, in collaboration with Deep Reality SRL and Moebeus Società Benefit SRL.
Stay tuned as we share updates, insights, and behind-the-scenes moments from this exciting project!