In spring 2001 ThyssenKrupp Gerlach GmbH has commissioned a new production line for manufacturing crankshafts. Although nearly automated packaging for shipping has to be done manually due to customer demands. The final layout of the corresponding workplace is based on a 3D man model (ANTHROPOS ErgoMax), which has been used for virtual design and evaluation.The ergonomic analyses of the preliminary workplace layout with the 3D man model showed serious problems when depositing the crankshafts. Therefore different workplace layouts related to this work element were developed, compared and rated. Finally the most ergonomic solution was found as a combination of height adjustment and a 180° turn of the transport containers to optimize working conditions. In addition vision analyses and studies where to position the controls were carried out using the man model.The application of an ergonomic software tool based on a 3D man model to design the workplace has resulted in significant improvements of the workplace and the prevention of health risks even before a real person has started to work.