Table of Contents
1. What are the specific constraints of production spaces?
2. What ergonomic solutions are available for production areas?
Improving the ergonomics of workstations in industrial manufacturing or garment production environments is no easy task….
In fact, these spaces present numerous environmental and postural challenges, on the one hand, and vary greatly from one another, on the other, so that each situation requires a tailored response.
"The industrial and manufacturing sector has historically been the cradle of research into the relationship between the human factor and the work factor, as well as the origins of ergonomics."
Within the industrial sector itself, there is a wide variety of fields (food processing, pharmaceuticals, automotive, etc.), job roles (part machining, packaging, maintenance, production, etc., whether at a workstation or on a production line), and work environments (cold, cramped, noisy, etc.).
Every work situation presents specific health and ergonomic challenges, which can be addressed by a variety of technical solutions, such as multi-position chairs or specialized upholstery.
What are the specific constraints of production spaces?
There are two categories of constraints faced by professionals in production environments:
1. Environmental constraints:
- Strict hygiene
- Extreme cleanliness (cleanrooms or sterile environments)
- Heat
- Cold
- Oily media
- Risk of splashes and stains
- Uneven ground, space constraints
- Noise
- …
2. Constraints related to the tasks performed:
- Working at heights or at very low levels
- Load port
- Prolonged standing
- Repetitive movements
- Need for range of motion and mobility
- Use of Machinery
- …
Faced with these constraints, the body adapts, and workers are forced to adopt painful postures—especially since production machinery cannot be modified or adjusted as easily as, say, a desk in an office setting. Uncomfortable postures can be avoided by installing ergonomic equipment. When it comes to shared workstations, this equipment must accommodate a variety of body types and uses (number of adjustments, range of motion, customization) and be easily adjustable.
What ergonomic solutions are available for production areas?
There are three types of technical solutions that can be used to address the constraints of production spaces:
- Posture-Related Solutions
- Material-handling equipment
- Personal Protective Equipment (PPE)
Here, we present only those solutions designed to reduce biomechanical stress and improve the worker’s posture. Of course, these solutions are intended to complement a comprehensive ergonomic and preventive approach (which will incorporate aspects of work organization, management, etc.).
Ergonomic solutions position operators in postures designed not only to prevent pain and the risk of musculoskeletal disorders, but also to ensure greater comfort on the job and improved productivity.
Height-adjustable countertops
The installation of height-adjustable workstations and work surfaces promotes proper operator posture, relieves physical strain, and allows users to alternate between sitting, standing, or a sit-stand position while performing tasks such as inspecting parts. At multi-operator workstations, the work surface adjusts to the heights of multiple users with different body types.
Ergonomic chairs
Thanks to their many features (seat design, mechanics, upholstery, base size, armrests, sturdiness, etc.), ergonomic chairs can address a variety of challenges in industrial settings.
Improving Posture
For example, for a maintenance technician working on machines in awkward positions—such as lying on his back near the floor with his arms raised—we can offer one of our ergonomic multi-position chairs. These chairs allow the user to move around without having to stand up, while providing support for the back all the way up to the neck and relieving pressure on the joints.
For tasks that require leaning forward over a work surface—such as a lab technician working at a microscope or a welder— a chair with a chest rest can provide good support and relieve strain on the back and arms.
At workstations equipped with a monitor and/or a computer, traditional stools should be replaced with sit-stand chairs that provide greater lumbar support. It is essential that the seat and backrest be able to rotate so that the operator does not have to turn their torso, which could lead to pain or injury.
For production tasks typically performed while standing—during which workers are often prone to being stepped on and experiencing back pain—use a sit-stand chair allows you to maintain mobility while providing back support.
If the work surface is high—which is often the case for tasks requiring precision and dexterity, such as welding—there are special seats or lifting cylinders available to raise the operator and reduce strain on the shoulders and back. In this case, to minimize the risk of falling, casters with load-sensing brakes should be installed. A circular footrest can also be installed on the seat.
Adapting to the Work Environment and Work Organization
On a production line where space is limited (carts, accessories, computer workstations, etc.), a compact base will save space and improve maneuverability.
Chair casters can also be selected based on the type of flooring. For example, in rooms that are regularly cleaned with water and have wide floor grating, casters with a large diameter should be chosen.
If the workstation is shared, we recommend a chair with a wide range of adjustment options that are simple and quick to use, with few controls, so that each user can adjust it to fit their body type without wasting time.
Simple solutions exist even if the workstation (lab bench, workbench) cannot be modified, as is often the case. For example, for an operator who cannot fit their legs under the lab bench because it has drawers, we can suggest a saddle-style seat, which will allow them to move closer to the workbench, sit up straighter, and thereby reduce strain on the back and shoulders.
In certain situations, standing is still the preferred position, such as in oily environments. In such cases, non-slip and anti-fatigue mats can be provided to improve comfort while standing.
"There are simple solutions, even if the workstation can't be modified."
Arm supports
If the arms are not supported by the seat's armrests, you can install armrests or systems to assist with upper-limb movement.
These robots can relieve the operator of strenuous and precision tasks that require keeping the arms suspended (screwing, polishing, painting, packaging, etc.) and are used in a wide variety of applications (the pharmaceutical industry, watchmaking, maintenance, sewing, etc.).
Quality control tasks sometimes require very detailed visual inspection. The part being inspected must be at eye level. In such cases, the armrest effectively supports the arm, allowing the worker to maintain precision without experiencing pain in the upper limbs.
Acoustic Solutions
Noise is a significant issue in industrial settings and usually requires the use of specific PPE. Depending on the required level of noise reduction, we can offer acoustic solutions identical to those used in offices.
Materials
The materials used in ergonomic equipment must be considered early on and in accordance with the constraints of the work environment.
Let’s take the example of a worker who handles electronic components. This activity requires limiting electrostatic charge, so antistatic equipment must be provided as part of the workstation setup.
If the activity requires the use of solvents, and the equipment has casters (such as a chair, for example), be sure to choose appropriate treads, or the casters may melt from sliding on the solvents.
Stainless steel can meet hygiene requirements in the food industry: this material limits bacterial growth and facilitates thorough washing while minimizing equipment wear. The PU coating is easy to clean if the workstation is at high risk of splashes and/or dirt.
It should be noted that only chairs that meet specific requirements and standards are permitted in cleanrooms.
Given the demanding conditions in manufacturing and garment production environments, it is recommended to choose robust equipment with a long service life. This requirement for robustness also applies to multi-operator workstations operating on a 3-shift, 8-hour rotation, 7 days a week.