Ergonomics can only be fully effective if a workstation system is not only suitable for the current process, but can also react to changing requirements. Processes in intralogistics change regularly - material heights, container sizes, mix of variants or supply concepts. If working levels, transfer heights and functional zones remain inconsistent in the face of such changes, the very unrest that ergonomic design is supposed to prevent is created.
Process stability is therefore less a question of individual height values, but rather the capability of a system, map dynamic processes, without employees having to compensate. This is where the difference between ergonomically correct and ergonomically effective becomes apparent.
Level coordination instead of individual dimensions
Ergonomically suitable heights alone do not create stable workflows. The decisive factor is how the levels along the process to each other. A work surface can be set correctly - and yet there is still variation if the material feed is too low or the removal level does not match the axis of movement.
In an assembly application, the difference between the work surface and component provision was just over ten centimetres. Formally within the correct range, but practically a continuous axis change during movement. Not stressful, but sufficient to significantly increase the cycle variance.
Precise harmonisation of the transfer heights stabilised the process immediately - with the same cycle time and the same load.
Because processes change, such levels must Adjustable without conversions and without construction work.
Grip point stability - small deviations, big effect
Gripping spaces are established, but the decisive factor in day-to-day business is Grip point stability. The formal height is of little use if the actual grip point shifts due to changing container heights or fill levels.
The spare parts logistics showed:
The most common KLTs were formally in the correct belt, but their grip point varied by several centimetres depending on how they were filled. The employees were physically light, but mentally fragmented.
A height-constant intermediate carriage stabilised the grip point - and the error rate dropped measurably.
Stability comes from repeatability, not by ideal dimensions.
Functional zone logic - clear activities, clear movement
Many deviations in the process arise because activities are not clearly separated from each other. Visual work, gripping work, inspection steps and documentation often use the same area - this generates mental switching and search movements.
In a packaging process, the separation of gripping, viewing and document zones led to much clearer movement patterns.
The adjustments were small, but the effect was great: fewer interruptions, less variation, more stable bars.
Such structuring must be possible, without having to rebuild the entire workplace system.
Transfer heights as a process-defining factor
The greatest ergonomic effect is often achieved at HandoversRoller conveyors, flow racks, mobile trolleys or FIFO systems. If their end heights do not match the axis of movement, micro-adjustments occur that make the process unstable.
In a mechanical engineering project, a slight adjustment to the transfer height was sufficient to eliminate an unconscious forward tilt. The cycle time remained unchanged and the process was noticeably smoother.
Such points characterise the process quality - and often change when an assortment or replenishment concept is adapted.
Why modularity ensures an ergonomic effect in the long term
Ergonomics must not stop at the current process. Processes change in real environments:
- Variant change
- New container heights
- Seasonal peaks
- Additional test steps
- Changed supply concepts
- AMR or tugger train connection
If a workstation system remains rigid, it loses its ergonomic effect - even if it was originally planned correctly.
That's why we rely on modular pipe clamping technology in all projects - in three coordinated system worlds that cover different requirements and can be seamlessly combined with each other. LOGIFORM, ALUFORM and TETRIFORM make it possible to quickly adjust heights, levels and functional zones without welding or drilling. Transfers can be precisely adjusted, mobile modules can be integrated into the material flow and gripping areas remain stable - even when processes change.
This modular structure not only ensures flexibility, but also compatibility: the systems fit into common industry standards and expand existing solutions without disruption. This ensures that the ergonomic effect is maintained in the long term - regardless of how materials, variants or processes develop.
Conclusion
Ergonomics is not created by ideal dimensions, but by Consistent levels along the process - and by the ability of a system to adapt to changing requirements. Transfer heights, gripping points and functional zones must work together and remain variable.
Our project experience shows:
Even small, systematically planned adjustments reduce variation, stabilise processes and maintain an ergonomic effect in the long term.
