When designing the optimal workbench for an assembly plant, intralogistics activities and ergonomic requirements usually seem like opposites.
For example, ensuring logistics processes run efficiently means making it as easy as possible to restock workbenches with materials without needing any special aids. Manufacturers often deploy standard containers at workbenches, with little consideration given to how these containers are arranged in front of workers. As a result, semi-open fronted boxes are often lined up parallel to the edge of the table. Weight, frequency of picking, and even how far the worker can reach: none of these factors are taken into account.
From a logistics point of view, the ideal containers are easy to transport, stackable and take up little space. As a result, workers are confronted with large containers that can be difficult to work with when picking small parts. In cases like these, assemblers must adapt to their workbenches, move around a lot more than is necessary, and perhaps even adopt poor postures.
In contrast, when workbenches are designed according to ergonomic principles, everything revolves around adapting the working area to the skills and physical features of the worker. Key considerations include high-quality chairs and height-adjustable workbenches, easy movement of containers and crates, simple transport processes, and ideal material supply and picking arrangements. To avoid unnecessary movement at the workbench, it is essential that workers can easily access and sort small parts within their reach zone.
Resolving the conflict between logistics efficiency and ergonomics is the concept behind Item America’s new Ergologistics line of workbenches. The product line takes in the entire assembly process, from material supply and transport to production at the workbench.
For example, transport trolleys with smooth-running casters offer staff a safe and simple means of moving even heavy workpieces and materials from place to place. The lightweight bench has a high load-carrying capacity and optimized chassis. Carefully thought-out transfer points make it easy to move standard containers from transport trolleys to the bench. Shelves with a dropped edge on the resupply side make sure there is nothing to obstruct restocking operations. Semi-open fronted boxes and containers are arranged on several levels and automatically slide forward on sloping surfaces, so materials can be rapidly replenished in efficient quantities.
In the assembly area, grab containers are slotted directly into the tray stop profile or profile groove in front of semi-open fronted boxes to provide sorting surfaces for small parts. Workers can also remove the grab containers and place them directly on the work surface, where they are in easy reach.
Assemblers can arrange picking systems to suit the way they want to work. Rubber buffers fitted to the bottom of the grab containers ensure they sit securely on the tabletop. The ergonomic shape of the lip and the grooves on the bottom make it easy to pick out even the smallest parts, even from a range of angles. Color coding makes it easy to differentiate between contents, while a consistent labelling system means small parts can be ergonomically restocked and picked without the risk of mix-ups.
The workbenches are fully compatible with Item’s complete line of modular components, so they can be perfectly tailored to the needs of assemblers. For instance, grab containers and parts containers can be combined with pivot arms, allowing workers to adapt their workstation to suit their own personal reach.
Existing Item workbenches can be retrofit with Ergologistics components by equipping them with the appropriate uprights.
Besides parts bins and pivot arms, myriad accessories are available for the workbenches, including lighting, tool supports, and display arms.
The Ergologistics product line has earned a seal of approval from the Campaign for Healthy Backs, a German nonprofit associated dedicated to ergonomics and the prevention of back injuries.
For more information on workstations, material handling equipment and modular components, click www.item24.com or visit the company’s booth at The ASSEMBLY Show. Item is one of numerous suppliers of modular components that will be exhibiting at the show, which will take place Oct. 21-23 at the Donald E. Stephens Convention Center in Rosemont, IL. Others include Creform, Flex Craft, and Industrial Profile Systems.
Besides suppliers of modular components, you’ll find more than 130 suppliers of automation, fastening tools, presses, robots, motion control technology, parts feeders, workstations, software and other assembly technologies. For more information, visit www.theassemblyshow.com.
