How to Design the Ideal Assembly Workstation

Assembly work is an indispensable part of the modern manufacturing industry. Its development as a result of the decline of industrialization has made the world we live in today possible. Cars, IT infrastructure, and of course production machines themselves are all manufactured in this way. The advantages are therefore obvious, but assembly work can also have its downsides, as history has shown. According to philosopher Martin Heidegger, the danger lies precisely in this, that through technology, humans view nature as nothing more than a resource. However, they forget that humans themselves are part of this nature. Workplaces that are not designed ergonomically, with people as such in mind, pose an immense risk to the health of staff. For this reason, Shoes For Crews would like to explain the ideal design of such an assembly workstation today – so that maximizing profits and reducing risks go hand in hand in your company.

Risks of an Inhumane Workplace Design

The adverse working conditions that prevailed in most companies until the middle of the 20th century are a prime example of what happens when production fails to put people, as a vulnerable element, at the forefront. High injury rates, absences due to occupational illnesses, and resulting costs for employers and employee protests were the result. Fortunately, these conditions are now a thing of the past. We have recognized that the physical and mental well-being of employees is an asset worth investing in. But how can this be implemented? Find out more below.

Psychological Strain  

The heading already reveals the main causes of mental and physical strain in manufacturing at assembly workstations identified by research. Monotony poses an enormous risk to the health of the human organism. The BIBB/BAuA Employee Survey conducted in 2012 by the Federal Institute for Vocational Education and Training (BIBB) in cooperation with the Federal Institute for Occupational Safety and Health (BAuA) makes clear what employees suffer from:

• Approximately 50% of respondents suffer from monotonous, constantly recurring tasks
• 60% experience strong deadline and performance pressure
• 61% of respondents are given exact specifications for quantities, performance, and time
• Working to the limits of their personal capacity is reported by 16%

A certain level of performance pressure will always be present at assembly workstations by the nature of the work. The goal is therefore to find the right balance between efficiency and safety with regard to staff health.

Physical Strain

In addition to the psychological strain mentioned above, physical tasks also place demands on employees:

• 83% of respondents report standing work.
• 56% have to perform a particularly large amount of work with their hands. Employees are often exposed to noise and dirt.
• Half of the employees experience back pain.
• 43% suffer from neck and shoulder pain.

Ergonomic workplace design is of central importance here. Below, we summarize the most important factors for correctly designing an assembly workstation.

Implementing Ergonomics in the Workplace

The ETEM employers’ liability insurance association recommends designing workplaces to meet human needs from the outset. Subsequent redesign is generally not only more expensive, but also less efficient. For this reason, it has published a comprehensive guide that clearly explains what to consider:

1. Alternating between standing and sitting: Ideally, change posture up to 4 times per hour, with  standing phases lasting no longer than 20 minutes.
2. Working height: An upright and natural posture is ideal. The working height can differ significantly from the height of the work surface. Employees vary in height, so height-adjustable tables are essential.
3. High chairs: Correct use is important here: align the chair, turn the seat 90°, climb onto it, and swing it under the worktable.
4. Freedom of movement: Provide space at the table to use the work chair and work materials, and space under the table so employees can move their legs and feet sufficiently. Make the work surface spacious enough to allow smaller, individual changes or adjustments in the work area.
5. Reach zone: Arranging parts, tools, etc. within the employee’s reach enables efficient work through easy accessibility. Physical strain caused by one-sided and repetitive movements is reduced.
6. Visual task: Do not place materials outside the maximum field of vision; keep frequently needed materials in the optimal field of view and collection containers at the same distance from the employee.
7. Working environment: Temperature, humidity, and noise levels should be kept as close as possible to a level comfortable for people.

As we have seen, one of the most important factors—and also one of the easiest and most cost-effective to implement—is alternating between sitting and standing. The right footwear makes a major contribution to staff safety and well-being. 

Safety Shoes from Shoes For Crews for Assembly Work 

With our many years of experience in the field of safety shoes , we can help you protect your staff and minimize physical strain from standing at assembly workstations. The risk of slipping and tripping exists everywhere for employees in manufacturing and industry. Slip-resistant safety and work shoes from Shoes For Crews ensure that your workforce stays safe and comfortable on their feet all day. The outsoles of our shoes provide the necessary grip, durability, and safety. They also provide the necessary comfort, so your employees remain protected and comfortable even when standing for extended periods. Don’t wait—contact us today to equip your staff as effectively as possible for their working day.