What’s New in Process Simulate Human 2026?
Smarter human simulation, improved ergonomic analysis and more immersive virtual reality for modern manufacturing.
Designing an efficient manufacturing process is about more than machines, robots and production lines. It is also about the people who operate them.
Ensuring that workers can reach components, perform tasks safely and work comfortably is essential to creating productive and sustainable manufacturing environments.
With Process Simulate Human, part of the Siemens Tecnomatix portfolio, manufacturers can evaluate human interactions within a virtual manufacturing environment. By simulating tasks before a production line is built, engineers can identify potential ergonomic risks, improve workstation layouts and make more informed decisions.
The latest 2026 updates bring new capabilities for human modelling, ergonomic analysis and virtual reality, helping manufacturers create more human-centric production processes.
What is Process Simulate Human?
Process Simulate Human is a human simulation and ergonomics solution that enables manufacturers to analyse how people interact with products, equipment and manufacturing processes.
It supports a range of activities, including:
Human reachability and accessibility studies.
Walk path analysis.
Vision analysis.
Ergonomic assessments.
Human posture simulation.
Task and process validation.
Virtual reality-based manufacturing reviews.
By bringing human factors into the virtual planning process, manufacturers can identify potential issues earlier, before changes become costly to implement on the shop floor.
Key updates in Process Simulate Human 2026
1. Interactive human posturing
One of the key enhancements in the latest release is interactive human posturing, making it easier and more intuitive to position human figures within a simulation.
Users can interact directly with human figures in the graphics viewer using on-body controls to adjust and lock individual body parts. The workflow also supports automatic object grasping and quick access to posture libraries.
This reduces the need to navigate between different tools when creating and adjusting human postures.
Why it matters
Creating realistic human postures is an important part of ergonomic assessment. More intuitive controls can help engineers position human models faster, explore different task scenarios and refine workstation designs more efficiently.
For manufacturing teams, this means less time spent setting up simulations and more time evaluating how tasks can be improved.
2. AI Copilot for ergonomic analysis
Artificial intelligence is becoming an increasingly important part of engineering software, and Process Simulate Human 2026 introduces Copilot support for ergonomic analysis in Task Simulation Builder (TSB).
The AI Copilot helps users interpret simulation results and assess human workload. Engineers can ask questions about their TSB simulations, including the maximum loads a human can safely manage for each task.
By combining AI-assisted insights with simulation data, users can investigate ergonomic results more efficiently and gain a clearer understanding of potential risks.
Why it matters
Ergonomic analysis can involve reviewing detailed simulation results and assessing the demands placed on workers.
AI-assisted analysis can help reduce the effort involved in finding relevant information, allowing engineers to focus on improving task design and making informed decisions earlier in the planning process.
3. Explore human option
The new Explore Human option provides a way for users to introduce sample human figures into their studies without requiring a Human license.
Users can create male and female figures, position them within a study and apply postures from the Posture Library to visualise human interaction during manufacturing planning. This makes it easier to explore human-centric manufacturing concepts at an early stage.
Why it matters
Not every user involved in manufacturing planning needs advanced human simulation capabilities. The Explore Human option allows teams to visualise human interaction during the early stages of design before investing in more advanced functionality.
Additional Human licenses are required for advanced features such as figure customisation, scaling, simulation and ergonomic analysis.
4. More immersive virtual reality with haptic feedback
Process Simulate Virtual Reality helps engineers review manufacturing processes in an immersive environment.
The latest updates introduce collision notifications using haptic feedback and visual object ghosting when manipulating objects in VR.
Supported hand controllers can provide tactile feedback when collisions occur, while visual indicators help users identify where objects are interacting or interfering.
Collision notification preferences can also be configured within VR using the immersive preferences menu.
Why it matters
Virtual reality can help manufacturing teams experience and validate processes before physical implementation.
These enhancements make it easier to identify potential interference issues during assembly and disassembly operations, helping teams improve confidence in their virtual reviews.
5. PICO 4 Ultra headset support
Process Simulate Virtual Reality now supports the PICO 4 Ultra headset, expanding the range of hardware options available for immersive simulation.
This provides greater flexibility for organisations selecting VR hardware based on their technical requirements, deployment needs and budget.
For engineering teams, additional headset support can help make immersive manufacturing validation more accessible across different use cases.
How Process Simulate Human supports smarter manufacturing
Human simulation plays an important role in digital manufacturing, helping businesses consider the people who interact with production processes.
By evaluating human movement, posture, reachability and task demands in a virtual environment, manufacturers can explore improvements before implementing changes on the shop floor.
Reduce ergonomic risks
Identify potential issues with posture, reachability and human workload during manufacturing planning.
Improve workstation design
Evaluate whether operators can access tools, components and equipment comfortably and efficiently.
Validate processes earlier
Use virtual simulation to explore and assess manufacturing tasks before physical production begins.
Support better engineering decisions
Combine human simulation with broader digital manufacturing workflows to improve process planning and reduce the need for costly changes later.
Discover Process Simulate Human with Kaizen PLM
The latest Process Simulate Human enhancements demonstrate how human simulation, artificial intelligence and virtual reality are helping manufacturers improve the way they plan and validate production processes.
From interactive human posturing to AI-assisted ergonomic analysis and immersive VR reviews, these capabilities support a more connected approach to manufacturing engineering.
At Kaizen PLM, we help businesses explore Siemens Tecnomatix solutions and understand how digital manufacturing software can support their production planning, simulation and optimisation requirements.
Want to learn more about Process Simulate Human 2026?
Contact Kaizen PLM to discuss your manufacturing simulation needs and discover how Siemens Tecnomatix can help you design safer, more efficient and better-validated production processes.
#Process Simulate Human
#Siemens Tecnomatix
#human simulation
#ergonomic analysis
#manufacturing simulation
#virtual reality manufacturing
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