Manufacturing, Industrial and Production line Ergonomics

Ergonomic solutions for manufacturing environments (production lines, assembly operations), industrial operations (warehouses, logistics, heavy industry) and commercial environments (service environments, offices, retail operations).

Our Assessment Approach

Comprehensive Ergonomics Assessment

Our manufacturing ergonomics assessments are based on direct observation, precise measurements and detailed analysis of your workplace operations. We evaluate tasks, equipment and environment through employee consultation and workplace monitoring to identify ergonomic risk factors.

Where appropriate, industry-recognised assessment tools are applied, including:

  • MAC (Manual Handling Assessment Charts) – lifting, carrying and team handling

  • RAPP Tool (Risk Assessment of Pushing and Pulling) – force analysis

  • ART (Assessment of Repetitive Tasks) – upper limb repetitive work

  • RULA (Rapid Upper Limb Assessment) – upper body task evaluation

  • REBA (Rapid Entire Body Assessment) – whole-body posture analysis

All assessment reports include risk mitigation recommendations applying the Hierarchy of Control to identify and prioritise the most effective interventions.

AI-Powered Assessment Technology

As an additional or alternative assessment method, we can carry out AI-powered analysis. This approach uses smartphone video capture to generate HSE-standard reports (MAC, RAPP, ART, RULA, REBA) within minutes, with red/amber/green risk categorisation and 90%+ accuracy compared to laboratory-grade motion capture systems.

Benefits of This Approach:

  • Faster identification of high-risk tasks enables quicker interventions

  • Local teams can capture assessments themselves whilst maintaining expert support

  • Objective, consistent analysis across multiple sites and shifts

  • More time redirected towards implementing risk reduction measures

This technology enhances rather than replaces Ergonomics expertise. We provide the strategic insight, practical recommendations and implementation support that actually reduce injury risk.

What We Assess

Manufacturing Ergonomics assessments extend beyond posture and lifting to examine the complete working system:

Physical Factors
Assessed: Forces, postures, repetition, reach distances

Environmental Factors
Guidance: Lighting, temperature, air quality and noise levels

Organisational Environment
Pace of work, levels of Ergonomics awareness and workplace culture

Tools & Equipment
Design suitability, adjustability, usability and maintenance standards

Task Execution
Work as actually performed on the production floor, not just as documented in procedures, inefficiencies

Specialist Manufacturing Applications

Our production line Ergonomics expertise addresses:

  • Assembly line workstation optimisation and process design

  • Repetitive sub-tasks in machine tending operations

  • High-throughput production environments

  • Manufacturing support roles and control room operations

  • Warehousing and logistics tasks integrated with production

Common Ergonomic Challenges

  • Awkward Postures - Working above shoulder height, awkward reaching, working in confined or restricted spaces, prolonged standing or sitting

  • Repetitive Tasks - High-frequency movements causing strain and fatigue

  • Equipment Provision & Design - Inadequate workstation setup and tool selection, suitability and usability

  • Manual Handling - Lifting, carrying, pulling, pushing and moving equipment, materials or components

  • Environmental Factors - Poor lighting, temperature, air quality and noise levels

Our Production Line Services

  • Comprehensive Risk Assessment - Evaluation of tasks, equipment and environment through direct observation and employee consultation in actual workspaces.

  • Risk Mitigation Recommendations - All assessment reports include recommendations applying the Hierarchy of Control to identify and prioritise the most effective interventions.

  • Implementation Support - We can provide ongoing support to help you implement recommended changes, including engineering modifications, process changes and equipment improvements.

  • Environmental Guidance - Recommendations for lighting, air quality, temperature and noise levels for worker comfort and productivity.

Common Issues Addressed

  • Working height optimisation (to reduce working above shoulder height or bending)

  • Repetitive work patterns needing task rotation or automation

  • Prolonged standing or sitting requiring workstation adjustments

  • Poor visibility needing improved lighting or workspace layout

  • Manual handling tasks requiring equipment or process changes

  • Excessive force requirements in using tools, or pushing, pulling or gripping tasks

  • Adequate working space

  • Easy access to frequently used tools and equipment

Business Benefits

Manufacturing Ergonomics delivers measurable operational improvements:

Reduced Costs
Lower treatment and compensation expenses, plus indirect costs from backfill requirements, training, production downtime and supervision demands

Enhanced Productivity
Reduced fatigue, improved takt time adherence and smoother production flow

Quality Improvements
Fewer defects when posture, force application and line-of-sight are optimised

Workforce Retention
Lower recruitment and onboarding costs, reduced absenteeism and improved employee engagement

Regulatory Compliance

Our assessments support compliance with:

  • Management of Health and Safety at Work Regulations 1999

  • PUWER 1998 (Provision and Use of Work Equipment Regulations) – requiring work equipment to be ergonomically suitable

  • Manual Handling Operations Regulations 1992

  • DSE Regulations 1992 (relevant for manufacturing control rooms and support roles)

We also apply recognised international standards appropriate to Ergonomics and Human Factors, such as ISO 6385 (Ergonomic principles in the design of work systems), ISO 14738:2002 (Anthropometric requirements for workstation design at machinery) and ISO 11228 series (Manual Handling standards).

Benefits

  • Reduce musculoskeletal disorders (MSDs) and repetitive strain injuries (RSI)

  • Improve worker safety, comfort, efficiency and productivity

  • Address employee concerns and compliance requirements

  • Create people sustainable workplace improvements

Contact

Contact Ergo & Wellbeing to discuss your manufacturing, industrial or roduction environment ergonomic challenges.