Automation · Ergonomics
Automating a repetitive manual workstation
Illustrative project to automate repetitive gestures while retaining the operator for flexible, value-added operations.
Illustrative use case
01
Starting point
A workstation depends on repeated loading, unloading, checking or positioning. The operation is simple but labour-intensive and difficult to scale.
02
What needs to improve
- High repetitive-motion workload
- Throughput depends strongly on operator rhythm
- Variable cycle time
- Difficulties absorbing demand peaks
03
A solution to validate with the site
- Cycle observation and task decomposition
- Assisted or collaborative handling
- Simple fixtures and part presentation
- Interlocks and safe operating modes
- Manual fallback for flexibility
Illustrative use case — architecture and results must be confirmed using real site data and representative products.
Technical scoping sheet
What must be confirmed before designing the solution.
These points are intentionally practical: they prepare a site visit, trial or pre-study.
01Trigger+
Repetitive workstation with strain, limited throughput or high operator variability.
02Architecture to validate+
Gripper / cobot / indexing / simple checking while keeping useful manual tasks.
03Data to collect+
- Motion-by-motion cycle
- Product variety
- Ergonomics and operator zones
04Acceptance criteria+
- Stable throughput
- Fewer repetitive motions
- Simple changeover
05Watch points+
- Over-automation
- Too much product variety
- Operator-machine interaction
Key point
Keep flexibility where it has real value.
- Separate repetitive actions from judgement tasks
- Validate part presentation reliability
- Plan manual fallback and changeovers
Pre-qualification