New Work-In-Progress Video: Predicting the Effect of Restraint Systems on the HITL

The ability to place restraint systems on the human-in-the-loop (HITL) has been available in Santos Pro’s predictive human model since 2014, but it was a proof-of-concept that was not fully developed. Now, we’re working on this capability and want to show you our progress.

A client needs this solution for a project requirement, so we’re working to make this everything it should be. The advancements in our predictive human models are making this easier than it was five years ago to improve the addition of restraints. The idea is to make it so you can predict the effect of restraint systems on the HITL more easily using Santos Pro, which is a highly advanced, always-evolving digital human modeling program.

Please watch this video and let us know your thoughts about how you might apply this capability, which will be available soon.

And, in case you missed it, be sure to check out our other featured videos on YouTube.

– Steve Beck

Q&A with the CEO: What are the benefits of using Santos®?

This month’s Q&A with Steve Beck, CEO of SantosHuman Inc., addresses the benefits of Santos® to your company.

Q: What are the benefits of using Santos® technologies?

A: Let’s look at this question from 3 different perspectives, all in terms of reducing costs.  We’ll start with the U.S. Government because, frankly, SHI wouldn’t exist without them.  Then we’ll look at Private Industry and finally from the perspective of Safety.

U.S. Government

The original funding for what is now commonly referred to as Santos came from the U.S. Army Tank-Automotive & Armaments Command (TACOM) in 2003.  TACOM program managers explained their motivation for this program in the following way. They told us that the next generation tank would take approximately 13 years to go from white paper to production. Historically, within those 13 years, 9 physical prototypes would be required. Each of those physical prototypes would cost approximately $1B (2003) and 90% of that cost (funded by US Taxpayers) would be committed as soon as the contract to build the prototype was awarded. They also said that one of the critical reasons for creating these physical prototypes was to make sure Warfighter-in-the-Loop issues are understood and addressed prior to production because getting those wrong would cost lives.

Their initial assumption had been that an existing commercial, off-the-shelf (COTS) digital human model (DHM) could be deployed early enough within design cycles to reduce the number of physical prototypes required. This would reduce the cost of, not just next generation tanks, but any new system and allow better designs to be brought into production sooner. However, upon completing a survey of the COTS DHM options available, they determined none of them could be used to achieve this goal. What they said they needed was a way to predict what the Warfighter would do and the program funding, therefore, was a catalyst for DHM research that could lead to capabilities more closely aligned with US DoD DHM requirements.

In the world of Defense Contracting, Santos represents a Warfighter-Centric alternative to the traditional Trial & Error approach to system design that can save billions in taxpayer expenditures.

Private Industry

Many years ago, I had asked our contacts at one of the world’s largest automobile manufacturers what Santos technologies meant to their industry. Based on data from over 100 years of designing and manufacturing automobiles, they said every new vehicle design historically comes with about 5000 problems. Any of those problems that can be addressed prior to production represents a savings of about $50,000. And in the year this conversation took place, they indicated 9 new vehicles would be going into production.

Those numbers suggest $2.25B worth of cost savings if 100% of the issues could be addressed prior to production.  However, they also indicated that not all of those issues are human-centric. Paint, for example, might not cure correctly or hoses may not fit or door assembly mount points may be misaligned. While those are obviously not human-centric issues, they said anywhere between 10% and 20% of those 5000 issues are human-centric.

If you run those numbers and divide by 9 new vehicles, Santos represents savings of between $25M and $50M per new product for one company in a single year because Santos predictive models provide a unique ability to inform and support human-centric design decisions at the earliest stages of product development.


US companies spend between $50B and $70B per year on work-related injuries. In addition, our contacts within the U.S. DoD have said that the greatest source of lost days for Warfighters is due to equipment use. With that in mind, consider that an extensive study by two World-renowned ergonomists shows that commonly used tools to assess exposure to work-related risk of injury can be off by as much as 16 lbs. This means that even though your company may be assessing tasks for risk of injury, there’s a pretty good chance task risk is being under- or over-estimated.

Manufacturing analysisUnderestimating risk means exposing your workers to increased risk of injury and this is critical for 2 reasons. Not only does it impact the lives of your employees, cost of injury calculators indicate that a single back injury with a $100K payout can have a ripple effect throughout a company requiring an additional $4.2M in sales to offset the cost of just that one injury.

Overestimating risk means expensively and needlessly redesigning tasks that could safely be accomplished as originally designed. Either way, these costs significantly affect the bottom line of just about every company in every industry.  And this is why Santos technologies include the world’s most accurate and most extensively validated method of predicting exposure to risk of injury available today. Use this link if interested in finding out more.

Back to the original question.  What are the benefits of using Santos?  A better question might be, what does it cost to NOT use Santos?

Thanks for tuning in.  You can learn more about other Santos capabilities here and, as always, let us know what you think. We’d love to hear from you.

– S

Q&A with the CEO: What problem is Santos® meant to solve?

This month’s Q&A with Steve Beck, President & CEO of SantosHuman Inc. answers the question of what problems Santos is designed to solve.

Q: What problems are solved by Santos®?

Santos technologies provide a platform that enables our clients to look at humans-in-the-loop in a wide variety of applications. Our capabilities stand out as solutions to not one—but two—of the most persistent problems in product design.

  1. wheelchair analysisDesigning for Humans Earlier in the Process. The Santos first-principles approach to predicting physical human behavior and performance allows human-in-the-loop criteria to be considered at the earliest stages of product development. This enables our defense and private industry clients to design for increased performance and increased customer satisfaction from the start resulting in better designs that can be brought into production sooner. If you haven’t seen the recent blog series on this topic, you can find the first post in that series here.
  2. Predicting Exposure to Risk of Injury. A 12-year study by two world-renown ergonomics researchers involving thousands of subjects indicates that commonly used tools for assessing work-related exposure to risk of injury are not only inaccurate but can be off by as much as 16 lbs. Putting that into perspective relative to the lives of the workers your company employs, assume a task assessment underestimates the load a worker must handle by 16 lbs and your company has been given a green light on that task, which could be as much as 16 lbs. heavier than should be allowed. This means your workers could be performing a task all day, every day, that exposes them to a significant increase in risk of injury. With all of that in mind, consider that a) work-related injuries cost U.S. companies an estimated $50 to $70 billion per year and b) our defense clients have noted that U.S. warfighters lose the most days due to injuries associated with equipment use.lift analysis in Santos Pro

Let’s now assume a task assessment overestimates the load a worker must handle by 16 lbs and your company has been given a red light on that task, which could be performed with minimal exposure to risk of injury as originally designed.  When was the last time you saw a budget line item for unnecessary and expensive task redesign expenditures?

Whether you’re underestimating the loads your workforce can handle and exposing them to increased risk of injury -or- expensively and needlessly redesigning their tasks, relying on commonly and widely used tools for these types of assessments, most of which have been shown to be off by as much as 16 lbs., affects the bottom line of just about every company in every industry.

We worked closely with Professors Jim Potvin, Ph.D., and Nick la Delfa, Ph.D. to provide their solution – the most accurate and extensively validated method of predicting exposure to risk of injury for manual material handling tasks available today – within Santos products through the Arm Force Field Plug-In,

Learn more about other Santos capabilities and, as always, let us know what you think.  We’d love to hear from you.

– S

Introducing The Santos® Master Class Series on YouTube

If you want to learn more about how to use Santos Pro® or Santos Lite®, our new video series can help. We’ve introduced the first of four Master Class Series videos on our YouTube channel. The first video covers how to predict and simulate task-focused physical human behavior and performance. The second video tutorial shows how Santos Pro avoids collisions and vision obstructions.

Watch the videos here:

Please check back for more videos to be added to this series of tutorials, and contact us if you would like to learn more about Santos Pro® and its capabilities.