Today, ergonomics is better understood than it was 10 years ago. In recent years, it has become less of a standalone discipline and more of a lean manufacturing initiative.
In recent years, ergonomics has become less of a standalone discipline and more of a lean manufacturing initiative. “Ergonomic principles are consistent with the goals of lean manufacturing, such as waste reduction and simplified movement,” says Elleby. “Lean manufacturing focuses on using the minimum amount of resources to complete a project on time.”
Quarterman Lee, president of Strategos Inc. (Kansas City, MO), says lean elements, such as cellular production, 5S and visual controls, all address ergonomic issues. “Ultimately, value is added at the workstation level where products are built,” Lee points out. “Eliminating waste here is just as important as eliminating it through inventory, material handling and other areas.”
To address lean initiatives, manufacturing engineers are looking for flexible, modular workstations that can be easily reconfigured. For instance, legs equipped with casters are essential.
“Every workstation has to be mobile,” says Rice. “And, everything on the workstation has to be easily adjustable. It’s not just a wrist rest or a footrest. Drawers, monitors, shelves, dividers and bins all need to be easy and comfortable to use.
“Height adjustability is also key,” adds Rice. “Manufacturing managers are serious about budgets, return on investment and efficiency. Electrically or hand crank-operated workstations serve several practical purposes. These workstations can be used by different employees throughout the day without sacrificing comfort and safety. Even as a dedicated workstation, the operator has the ability to adjust it to various tasks and how they are physically feeling that day.”
Workstations must now be designed to accommodate a variety of workers, because lean production typically encourages sit-down, stand-up or stand-up and move methodologies. “This provides the most flexibility in a lean environment, while allowing employees to move through a range of motion that doesn’t encourage repetitive stresses on the body,” notes Greissinger. “Workstations made from T-slotted aluminum framing are often a good choice, because accessories can be placed anywhere along the T-slot. That allows the workstation to be tailored perfectly to the needs of each worker.”
The ability to easily install or remove a wide range of accessories and components is also an important consideration in today’s lean world. “An expansive selection of overtable and undertable accessories, such as adjustable storage shelves, bin rails, power, lighting, drawer storage, tool rails, pegboards, storage panels and computer peripherals, are essential in the design of lean workstations,” claims Lanctot. “End users are looking for the ability to purchase and add accessories as they need them, when they need them.”
Paperless work instructions are another lean-inspired trend that’s influencing workstation design. They allow operators to access and view standardized information with a computer display. Paperless systems save a tremendous amount of time and eliminate waste, because information does not have to be manually typed in from hand-written notes.
“With the introduction of monitors and computer components to replace paper work instructions, we have seen an incredible surge in related accessories,” says Verrill. “Slide-out, swiveling CPU holders and fully-adjustable flat-panel screen holders are a part of nearly every job we build lately.”
The challenge in going paperless is finding space at the workstation for the components that replace the paper system, such as a computer monitor. “The electronic components need to be part of the workstation without infringing on prime work space, while at the same time adhering to sound ergonomic principles that position these new work tools correctly in relation to the user,” warns Lanctot. “Also, any time you add something new to a workstation you have to consider how it will impact what you’ve already accomplished in terms of an ergonomically friendly work area. It’s a continual process.” A
To learn more about workstations and ergonomics, search for these articles on ASSEMBLY’s Web site: