Ergonomic Workstation for Industrial Assembly
Analysis of load distribution and lumbar support design for production line operators
The Challenge
An electronics component factory faced a high incidence of musculoskeletal injuries (MSDs) and premature fatigue among its manual assembly operators. The existing workstations, of generic design, did not consider prolonged static postures or the optimal distribution of tools, forcing spinal twists and overload in the lumbar region. The challenge was to redesign the workstation from a structural ergonomics approach, prioritizing active torso support and reducing biomechanical stress during 8-hour shifts.
Our approach was based on detailed mapping of body pressure points during repetitive tasks. We used pressure sensors and motion capture to model trunk tilt angles and weight transfer to support points. The technical design focused on creating a work surface with dynamic height and tilt adjustment, integrating an adjustable lumbar support that adapts to the natural curvature of the spine. The selected materials —light beech wood for contact surfaces and steel with a slate gray finish for the structure— offer durability and a technical aesthetic that integrates into the industrial environment.
Results and Validation
The implementation of the new design in a pilot line demonstrated a 62% reduction in complaints of lower back pain during the first three months. Efficiency studies showed an 8% decrease in cycle time per unit, attributed to better tool accessibility and the reduction of corrective micromovements. The adjustable lumbar support allowed the workstation to be customized for 95% of the operator population, according to anthropometric percentiles.
The materials confirmed their suitability, with the light wood providing a warm and non-slip surface, and the slate gray of the structure hiding marks from frequent use. The project included the creation of ergonomic adjustment manuals and training sessions for workers. As a result, the factory has scaled the design to its entire assembly plant, establishing a new internal standard for technical furniture. This case validates how design centered on structural ergonomics not only improves well-being but also translates into tangible gains in productivity and job sustainability.