Industrial Athlete

New methods in ergonomics
and occupational safety & health

The biomechanical measuring system INDUSTRIAL ATHLETE analyses musculoskeletal loads in real time and under real working conditions. Frequent load types such as force, forced posture and repetition can be identified for each body region and evaluated according to biomechanics and ergonomics criteria.

Forces and moments determined by IMU sensors are graphically animated and assigned to the activities performed using synchronized video recordings. This provides the ability to detect peak loads, to evaluate the effectiveness of tools, or to derive measures to avoid high musculoskeletal loads.

With its integrated data analysis and automated reports, the INDUSTRIAL ATHLETE enables fast and meaningful load assessments and ergonomic workplace design without the need for time-consuming procedures and human resources.

This opens a highly efficient way for companies to contribute specifically to the health, performance and motivation of their employees and to be able to offer attractive, healthy jobs on a permanent basis.

Visualize and quantify

Physical workload

Recognize health hazards

Real-time ergonomics analysis

Occupational musculoskeletal disorders (MSD) are a constant companion in working life. Our mobile ergonomic laboratory INDUSTRIAL ATHLETE helps identify the causes of illness, injury and damage directly at the workplace.

Identify exposure risks

Physical risk assessment

The employer has the obligation to carry out and document risk assessments. Using the INDUSTRIAL ATHLETE, this can be done quickly and comfortably, regardless of whether it is load handling, repetitive manual tasks, forced postures, high exertion or mixed activities.

Prevent musculoskeletal disorders

Workplace health promotion

The INDUSTRIAL ATHLETE is an impressive way of communicating good health behavior. At workshops or health days, he helps to explain back-friendly behavior, joint-preserving postures or the proper use of aids in a comprehensible way and to establish them permanently.

Biomechanics for healthy work


Consulting & Service

In companies that want to have their risk jobs or activities investigated, we carry out systematic load analyses directly on site using the INDUSTRIAL ATHLETE. Our ergonomics experts present the results in company workshops and provide suggestions for ergonomic workplace design and behavioural prevention.

Purchase & Support

For companies with a high or regular need, we offer the purchase of our measuring system INDUSTRIAL ATHLETE. In addition to ready-to-use measurement technology, the system package includes extensive training on hard- and software as well as free software updates for two years.

Range of application

Corporate consulting
Workplace inspections
Ergonomics analysis

Stress-strain concept
Risk assessment
Workplace design

Behavioural prevention
Health days

The mobile lab for ergonomics

Industrial Athlete

The biomechanical measuring system INDUSTRIAL ATHLETE, developed by scientists of the German Sport University Cologne, combines modern inertial sensors, biomechanical models and load weights. Portable over the workwear, the Motion Capture System enables ergonomic analysis directly at work or via VR glasses on the CAD model of your work environment. The evaluation software provides a real-time assessment of postures, movements and physical load (according to DIN, ISO, etc.) and displays them as biofeedback using a 3D avatar and animated body symbols.

The current occupational and biomechanical evaluation criteria of the German Social Accident Insurance are used (DGUV Information 208-033). On the basis of the measurement data, risk assessments can be compiled and statements made about necessary measures for ergonomic workplace design, compliance with physiological stress limits and prevention of occupational health hazards. For documentation and further processing, it is possible to export the recordings as video (Full HD), data table (csv) and analysis report.

New Standards

Analysis, assessment and (re)design
of demanding workplaces

  • Easy handling and minimal set-up time
  • Load analysis and biofeedback in real time
  • Optional integration of CAD workspace models
  • Automated hazard reports
  • Key indicator method: Lifting, holding, carrying

The application of the measuring sensors as well as the operation of the measuring software can be learned quickly and carried out independently by trained personnel after a short training period. The INDUSTRIAL ATHLETE is thus one of the fastest and most precise methods of analysis in the field of human science.


  • Workplace and ergonomics analyses (targeted or during inspections)
  • Physical risk assessments (according to ArbSchG §§ 5-6)
  • Types of load such as load manipulation, forced postures or (repetitive) manual activities
  • Planning and optimization of (sample) workplaces and workflows Instructions for safe and healthy work
  • Training and workshops on conditional and behavioral prevention
  • Health days and prevention projects (physical stress in everyday life and leisure)

Target Groups & Service Spectrum

The measuring system is used in the following areas:

  • Work-Health-Management: Practical measures on occupational safety and health
  • Occupational Safety: Physical risk assessment and stress-strain concept
  • Occupational Health: Prevention of musculoskeletal disorders and healthy workmanship
  • Ergonomics Consultants: Employee training on load -reduced behavior and ergonomic workplace design
  • Training and Education: Job-related, research-based teaching and learning in work science and health-promoting professions


  • Portable IMU measuring system for kinematic full-body detection (including a handy carrying case)
  • Small, lightweight sensors with appropriate Velcro strap attachment
  • Simple, easy-to-learn handling (1 day)
  • Short set-up time and easy calibration (ready-to-go in 10 minutes)
  • Unrestricted freedom of movement through wireless data transmission (WLAN)
  • Wearable above or below work wear or PPE
  • Mobile and flexible in field and laboratory
  • Expandable to capture the finger movements
  • Autonomous power supply with up to 6 hours runtime
  • Recording frequency up to 120 Hz
  • Small file sizes for efficient database storage and remote evaluation
  • Easy recalibration of magnetized sensors
  • Replaceable fasteners and sensors


  • Playback of the movement data as a 3D avatar
  • Real-time calculation of physical stress and strain:
    - Joint angle of head, trunk, shoulder and hand
    - Disc compression and shoulder torque
    - Work above shoulder level
  • Parameter evaluation according to traffic light scheme and DGUV guidelines
  • Cumulative indication of duration and frequency in range of limited conditions
  • Optional integration of CAD workplace models
  • Individually configurable parameter boxes
  • Individual model adaptation to height and weight
  • Load-weight input via keyboard in the current program
  • Adjustable distribution of load between hands
  • Recording of the travelled distance
  • Parameter reset at the touch of a button
  • Data-, photo- and video export (Full-HD) with a mouse click
  • Virtual Reality (VR) and Augmented Reality (AR) (planned realization: end of 2019)

Parameter Overview

The selection, position and size of the parameter boxes is variable and can be adapted to the respective work and load-specific requirements. Up to four individual configurations can be saved as a template. The parameters are evaluated according to the traffic light scheme on the basis of the currently valid DGUV guidelines (DGUV Information 208-033).

Companies investing in the health of their employees today will benefit from increased attractiveness, improved performance and sustainable competitiveness tomorrow. We support you with state-of-the-art methods and scientific expertise.

Our Concept

Is offered to companies that want to specifically reduce musculoskeletal disorders and physical strain in the context of workplace health promotion (WHP). The focus is on the systematic assessment of working conditions (ArbSchG §§ 5-6) and an innovative and comprehensive ergonomic workplace design to increase the well-being and performance of all employees.

The basis of our analysis is the INDUSTRIAL ATHLETE measuring system. It offers the best possible support for occupational safety and health in measures to:

  • Ergonomic workplace design
  • Compliance with physiological stress limits and
  • Fatigue and damage-free workmanship

Our Team

Consists of biomechanics, occupational scientists and orthopedists with special expertise in stress-load analysis, the interaction of man and work equipment and the prevention of work-related musculoskeletal disorders. As part of an interdisciplinary network with many years of experience at the German Sport University Cologne as well as in the field of occupational safety,

we accompany companies with scientific competence and state-of-the-art examination methods. Our services are characterized by high flexibility, short processing times and a good price-performance ratio.


Dr. Frank Emrich is a scientific assistant at the Institute for Biomechanics of the German Sport University Cologne and founder of scalefit. After studying sports science, he obtained his doctor's degree in biomechanics (2000) under Prof. Dr. G.-P. Brüggemann. His expertise includes occupational biomechanics and ergonomics in research and teaching. He headed the prevention projects "RWE – power line mechanics" and "Evonik – coal-fired power plant operator" as well as the widely acclaimed prosthetic study "Oskar Pistorius".

From 2014 to 2016 he worked as a research assistant at the OSH-Institute of the German Social Accident Insurance in Sankt Augustin. As part of the MEGAPHYS project, he conducted a large number of occupational scientific examinations using the CUELA measuring system.

As Managing Director of scalefit, Dr. Frank Emrich develops and sells the mobile ergonomics laboratory INDUSTRIAL ATHLETE – an innovative biomechanical measuring system for occupational safety and WHM.

In addition, he carries out physical risk assessments and ergonomic analysis in various companies using the real-time measuring system. He is a member of the German Society for Work Science (GfA), the Ergonomics Competence Network (ECN) and an international panel of experts for the evaluation of dynamic office workplaces.


Atlas Sicherheitsschuhe



Gesellschaft für gute Arbeit

Hochschule für Angewandte Wissenschaften Hamburg

Kautex Textron




TSV Bayer Dormagen Gesundheits GmbH
– Premiumpartner –


5 good reasons

for healthy work


Ergonomics creates a safe working environment.


Ergonomics reduces costs.


Ergonomics increases productivity.


Ergonomics improves quality.


Ergonomics increases employee satisfaction.