Empowering Assembly Work at MAN Energy Solutions: How the OmniSuit Supports Employees in Heavy Industrial Environments

About MAN Energy Solutions

MAN Energy Solutions in Zurich develops and produces large-scale compressors and turbines for industrial applications worldwide. The site plays a key role in advancing energy-efficient technologies. Employees there often face physically demanding tasks that require strength, endurance and focus.

How the idea became a project

The initiative to explore exoskeletons originated directly from the workforce. Employees suggested trying wearable support systems to ease physical strain in daily tasks. Their input sparked a structured evaluation process, during which four different providers were assessed for functionality, comfort and suitability for industrial use.

“Auxivo came out on top across the board, offering a solution that aligned well with our needs on site,” says Clemens Brunner, Process and Project Engineer at MAN Energy Solutions.

Soon after, the first exoskeletons were introduced. Today, a total of 25 exoskeletons are in use at MAN Energy Solutions in Zurich, including 12 OmniSuits – a lightweight multitask exoskeleton that supports both the back and shoulders. Designed for dynamic tasks such as lifting and overhead work, it provides flexible relief during a wide range of activities without limiting mobility, making it ideal for demanding industrial environments.

A smooth and collaborative implementation

Following the decision, implementation progressed quickly.

“Auxivo provided excellent guidance throughout the process,” Clemens explains. “Employees were trained on how to wear and adjust the devices properly. Whenever questions came up, the Auxivo team was responsive and available.”

Because the idea had come from within the team, openness was high from the start. Some employees were initially curious or cautious, but most quickly saw the potential after trying the exoskeleton themselves.The main challenge was establishing a habit of incorporating the exoskeletons into everyday routine. Through internal communication, reminders, and collaboration between departments, the exoskeletons gradually became a familiar part of day-to-day work.

Field study: measurable support for the body

To assess the impact of the OmniSuit, a joint field study was conducted by MAN Energy Solutions and Auxivo. The goal was to provide additional, company-specific physiological data to understand the level of support individual workers received during the tasks they performed in their daily work. This data was collected to inform evidence-based decisions where exoskeletons offer the most benefits.

A total of thirteen employees from different departments participated, some had prior experience with the OmniSuit, others tried it for the first time. Muscle activity in the back and shoulders was measured during real work tasks – both with and without the exoskeleton.

The results speak for themselves:

• Average reduction of 22% in muscle activity in the lower back

• 40% reduction in the upper back

• 40% reduction in the shoulders as well

These objective findings match the users’ experience: on average, they reported a 25% decrease in perceived strain, and 85% felt supported by the exoskeleton during their work.

What it means on the ground

In daily work, the impact of the OmniSuit becomes especially clear during repetitive or physically intense tasks. Workers who use the exoskeleton report that they feel noticeably less fatigued after their shifts.

Alberto Moreira is an assembly worker at MAN Energy Solutions. He has been using the OmniSuit regularly for several weeks. He sees the biggest difference at the end of the workday.

“I feel less tired after my shift. I still have energy left, even on Fridays. That’s when I really notice the benefit.”

One task stands out for him in particular: mounting heavy bolts.

“Each one weighs over 15 kilos. When you do that 20 to 30 times in a bent position, it’s tough. The OmniSuit really takes the edge off.”

Sacha Suter works at the pressing station and has been using the exoskeleton for about six months. He also had some initial concerns.

“My first thought was that it looked big. I wondered if I’d still be able to move freely. But I quickly realized that it’s comfortable and doesn’t restrict me.”

He handles large compressor parts and works in all kinds of awkward positions.

“The OmniSuit supports my back and arms. When you work with heavy equipment every day, it makes a noticeable difference. It’s a tool that fits my job.”

Looking ahead: health and performance

For MAN Energy Solutions, the benefits are both human and economic. Reducing physical fatigue helps preserve long-term health, especially in roles that require repetitive lifting or awkward postures.

“We want our employees to stay healthy and capable of doing their work until retirement,” Clemens says.

At the same time, productivity gains are already noticeable. With less fatigue, employees can maintain performance levels throughout the day. Retention is another important factor:

“If work feels less exhausting, people stay motivated longer. We expect lower turnover and, potentially, fewer accidents due to higher alertness.”

Overall, MAN Energy Solutions' experience shows that exoskeletons can be a valuable tool when implemented thoughtfully.

“It’s not a one-size-fits-all solution. But if you involve the people on the ground and select the right tool for the task, the impact can be significant.”

Curious how our exoskeletons could support your team?

Get in touch with us to learn more about how our exoskeletons can be integrated into your operations. Together, we’ll find the right solution for your workplace.