Ergonomics is well established in the industry. However, the actual effect is not evident in the design, but in the ongoing process. The extent to which ergonomic measures influence stability, quality and efficiency becomes apparent when processes are considered in their entirety - where movement, material flow and information logic are intertwined.
Ergonomics is therefore not an isolated design aspect, but part of the process quality. It ensures that movements remain logical, material flows run smoothly and cycles are reproducible. It is precisely in this reproducibility that your economic leverage lies.
Recognising bottlenecks - where movement comes to a standstill
Ergonomic deficits often only become apparent in the interaction between the person, the material and the cycle. Indications are unsteady grip patterns, additional steps, searching movements or small interruptions that add up over the course of the day.
Example from pre-assembly:
Employees were leaving the gripping area several times per cycle to retrieve parts. A modified depositing geometry and a short roller conveyor completely eliminated these paths. The result: around eight per cent shorter cycle times - with unchanged effort and identical quality. The improvement was achieved less through a „new dimension“ than through a more logical sequence of movements.
Practical note:
The ergonomic effect becomes tangible when you consider the frequency of grips and position changes in relation to the cycle time. Two simple counts are often enough to prioritise the next layout correction.
Stability beats peak value
Ergonomic design does not aim for maximum speed, but for consistency. Consistent processes without corrective movements usually produce higher output across shifts and variants than any temporary peak performance.
Example from the packaging:
Following the introduction of height-adjustable work surfaces, the average cycle times remained virtually unchanged. However, the fluctuations between the early and late shifts fell by almost 20 per cent. The result was less rework, a smoother material flow and more reliable scheduling.
Practical note:
When it comes to the effectiveness of ergonomic measures, the variance is often more meaningful than the mean value. A decreasing standard deviation of the processing time is a robust indicator of process stability.
Relieve information logic - cognitive ergonomics in the process
As the number of variants increases, so does the importance of clear information management. The decisive factor is not the amount of information, but its relevance at the moment of execution.
Example from final assembly:
A digital assistance system displays step sequences in context, scanner feedback is provided in the reach zone and displays are positioned at eye level without glare. The error rate fell measurably because the gaze and grip paths matched and feedback was clear.
Practical note:
Information changes count like movements: Every avoidable diversion of the gaze costs time and concentration. A joint consideration of reach space and field of vision prevents cognitive relief being „paid for“ elsewhere by additional movement.
Linking material flow - ergonomic supply instead of improvisation
An ideally designed workstation loses effectiveness if the supply does not match the cycle. Irregular replenishment leads to intermediate storage, searches and additional handling - classic sources of ergonomic restlessness.
Example system network:
Cycle-based supply via tugger train or AMR, defined approach points at an ergonomic height, standardised transfer areas. The combination reduced interruptions and made the process predictable. The ergonomic effect lay less in the individual table than in the synchronisation of workstation, replenishment and information.
Practical note:
The system can be used to manage replenishment cycles as a fixed parameter. A simple andon signal (visual/acoustic) in the event of a deviation from the target rhythm prevents spontaneous, ergonomically unfavourable replacement movements.
Digital feedback - measure without changing the process
Digital systems are not the opposite of ergonomics, but provide neutral feedback on the process. Sensors, counters or assistance systems automatically record grip frequencies, processing times or waiting phases and make patterns comparable - between shifts, variants or optimisation stages.
Example of measuring effect:
Time stamps per work step showed recurring delays at one station. The cause was not a performance weakness, but an unfavourable stacking height when changing variants. After adjusting the gripping points, the cycle stabilised; at the same time, the error rate in the quality check fell.
Practical note:
A few well-chosen key figures are sufficient: Handle frequency, interruption rate, deviation from the target cycle. Observation over time is important - trends are more relevant than individual values.
From the workplace to the system - ergonomics as a unifying principle
Physical, cognitive and process-related ergonomics are not separate disciplines. Their interlocking is decisive in the application. A workstation can be physically optimal - but if the information logic does not fit or the replenishment runs asynchronously, the overall process remains unstable.
The strongest effects are therefore achieved where design, supply and guidance are planned together: defined reach spaces, clear lines of sight, standardised handovers, cycle-based supply, digital feedback. The result is process calm - perhaps the most important indicator of modern ergonomics.
Practical impulses - small levers, big impact
- Prioritise reach-in spaces: Frequently required parts within 50-60 cm, rare parts at the edge of the natural radius. Count the number of handle changes per cycle and reduce them accordingly.
- Standardise transfer points: Standardise height, position and docking points between tugger train/AMR and workstation; search times are reduced, variant changes remain manageable.
- Clarify information interfaces: Display at eye level, scanner within reach, clear feedback; align gaze and grip path.
- Check constancy: Observe three variables for a fortnight after each layout change - error rate, grip frequency, interruption rate. Stability is the best proof of effectiveness.
- Secure temporary stations: For pop-up workstations, use modular height adjustment and preconfigured transfer surfaces; this keeps the quality constant despite the short ramp-up phase.
Conclusion
Ergonomics is a stabilising element of process design. It makes processes predictable, quality reproducible and performance plannable. Its effect is not created in the details, but in the system - where the logic of movement, material rhythm and information management fit together.
NeoLog develops workplace systems based on precisely this understanding: solutions that arise from real processes and combine ergonomic design, logical material flows and digital connectivity. This turns ergonomics from an aspiration into industrial reality - measurable, reproducible and economically viable.
