Employees at Ford's Valencia Engine Assembly Plant, in Spain, are using a special suit equipped with advanced body tracking technology. The pilot system, created by Ford and the Instituto Biomecanica de Valencia, has involved 70 employees in 21 work areas.

Player motion technology usually records how athletes sprint or turn, enabling sport coaches or game developers to unlock the potential of sport stars in the real world or on screen. Ford is using it to design less physically stressful workstations for enhanced manufacturing quality. The skin-tight suit consists of 15 tiny movement tracking light sensors connected to a wireless detection unit. The system tracks how the person moves at work, highlighting head, neck, shoulder and limb movements.

Movement is recorded by four specialised motion-tracking cameras - similar to those usually paired with computer game consoles - placed near the worker and captured as a 3D skeletal character animation of the user. Specially trained ergonomists then use the data to help employees align their posture correctly. Measurements captured by the system, such as an employee's height or arm length, are used to design workstations, so they better fit employees.