  During the conceptual and prototype design stage of an industrial product, it
is crucial to take assembly/disassembly and maintenance operations in advance.
A well-designed system should enable relatively easy access of operating
manipulators in the constrained environment and reduce musculoskeletal disorder
risks for those manual handling operations. Trajectory planning comes up as an
important issue for those assembly and maintenance operations under a
constrained environment, since it determines the accessibility and the other
ergonomics issues, such as muscle effort and its related fatigue. In this
paper, a customer-oriented interactive approach is proposed to partially solve
ergonomic related issues encountered during the design stage under a
constrained system for the operator's convenience. Based on a single objective
optimization method, trajectory planning for different operators could be
generated automatically. Meanwhile, a motion capture based method assists the
operator to guide the trajectory planning interactively when either a local
minimum is encountered within the single objective optimization or the operator
prefers guiding the virtual human manually. Besides that, a physical engine is
integrated into this approach to provide physically realistic simulation in
real time manner, so that collision free path and related dynamic information
could be computed to determine further muscle fatigue and accessibility of a
product design
