Fraunhofer Institute for Material Flow and Logistics IMLA shortage of skilled workers, increasing workloads, and digitalization are presenting new challenges for companies in production and logistics. Today, an ergonomic workplace is created through the interplay of people, processes, technology, and the work environment – physical and psychological demands must be considered equally. Fraunhofer IML provides companies with scientifically sound support: from analysis and the development of measures to the testing of new solutions.
Ergonomic workplace: Analysis & design
Ergonomics in transition: Scientifically designing ergonomic workstations
The requirements for ergonomic workplaces have fundamentally changed in recent years. While ergonomics used to be associated primarily with reducing physical strain, the focus today is increasingly on complex work systems. Automation, robotics, artificial intelligence, and digital assistance systems are transforming workflows and creating new forms of collaboration between people and technology.
As a result, the requirements for ergonomic design are also evolving. In addition to classic issues in physical ergonomics – such as lifting, carrying, or poor posture – cognitive ergonomics is gaining increasing importance. It deals with human mental processes – in particular perception, attention, information processing, memory, and decision-making – as well as their significance for the design of information flows and interaction with digital systems. The goal is to manage mental strain appropriately and reduce the risk of errors.
An ergonomic workplace is therefore not created solely through individual aids or technologies. The key lies in the interaction between people, work processes, technology, and the work environment. The goal is to design work systems so that physical and cognitive demands match the abilities and needs of employees. This reduces physical and mental strain while promoting health, occupational safety, and productivity in equal measure.
Independent ergonomic expertise for your company
Support in designing ergonomic workstations
Fraunhofer IML combines established ergonomic assessment procedures with innovative analysis methods and technologies to scientifically evaluate physical and mental stressors as well as ergonomic potential. We combine objective measurement methods, subjective employee assessments, and structured observation procedures to obtain the most comprehensive picture possible of the actual work situation.
Analysis & evaluation of ergonomic workstations
- Systematic Analysis of Physical and Mental Strain
- Combination of objective measurement methods, employee surveys, and structured observation methods
- Motion analysis using motion capture and Motion-Mining®
- Assessment of work environment conditions (lighting, noise, reach zone) based on ergonomic standards and the Technical Rules for Workplaces (ASR)
- Support for risk assessments of physical and psychological stressors
Technology evaluation & practical testing
- Manufacturer-neutral evaluation and comparison of ergonomic technologies
- Testing in the Picking Lab: Testing of robotic solutions, order-picking technologies, and digital assistance systems, as well as training for employees
- Testing in the Exoskeleton Lab: Evaluation and selection of exoskeletons, as well as training for employes
Consulting & support
- Development of technical, organizational, and personnel-related measures
- Support from analysis through to the successful implementation of new technologies
- Independent, manufacturer-neutral consulting based on scientific principles
Ergonomics Quick Check
The Ergonomics Quick Check is the ideal starting point for companies that want to systematically analyze workstations and improve their ergonomics. In a selected work area, we analyze physical and cognitive ergonomics, assess strain factors, and identify areas for improvement – based on objective measurement methods, employee surveys, and structured observation procedures, supplemented by motion analyses using motion capture. In addition, we evaluate work environment conditions such as lighting and noise, as well as reach zones, in accordance with the Technical Rules for Workplaces (ASR) and ergonomic standards. The results lead to a concrete catalog of measures based on the STOP principle.
Your benefits:
- Analysis of the workplace, work tasks, and work environment
- Assessment of physical and psychological stressors
- Support with risk assessment
- Well-founded recommendations for action to serve as a basis for decision-making
Target audience: Companies in all industries that want to reduce workloads and promote healthy and productive working conditions.
Usability Quick Check for digital technologies
Today, an ergonomic workplace also includes the ergonomic design of digital technologies. Software ergonomics has a significant impact on efficiency, user acceptance, and workplace safety in everyday work.
With the Usability Quick Check, Fraunhofer IML evaluates hardware and software, digital assistance systems, mockups, and prototypes in terms of usability, user experience (UX), and software ergonomics. In doing so, we analyze graphical user interfaces (GUI), information presentation, operating concepts, and the interaction between people and technology. Following a joint needs analysis, we evaluate solutions using employee surveys, focus group workshops, and expert assessments based on established standards. In addition, we analyze control elements and reach zones according to ergonomic standards and use objective motion analysis (motion capture). Depending on the stage of development and the specific use case, the evaluation takes place in the Fraunhofer IML Picking Lab, directly at the company’s premises, or at the technology providers’ facilities.
Your added value:
- Evaluation of hardware and software, assistance systems, mockups, and prototypes
- Analysis of usability, UX, GUI, and operating concepts
- Support with technology selection and benchmarking
- Increased acceptance, safety, and efficiency
Target audience: Technology manufacturers, software providers, and companies that develop or use digital technologies.
From analysis to appropriate measures
Ergonomic workplace design begins with a systematic analysis of working conditions since not every challenge requires the same solution. These assessment procedures and analytical methods help identify physical and psychological stressors:
- Workstation observations & employee surveys to capture subjective assessments
- Motion capture for the objective analysis of movement patterns
- Motion-Mining® for data-driven analysis of real-world work processes
- Usability & UX evaluations to assess digital systems and assistive technologies
The insights gained form the basis for selecting appropriate measures to design ergonomic workplaces. At Fraunhofer IML, we adhere to the principles of occupational safety and develop solutions based on the STOP principle. Substitutive, technical, organizational, and personnel-related measures are systematically examined and evaluated for their effectiveness.
“Wherever people are exposed to specific demands in their work environment, there is potential to design working conditions that are tailored to human needs. Our goal is to support companies with scientifically sound analyses so they can make the right decisions for healthy, safe, and productive workplaces.”
Dr. Veronika Kretschmer, Senior Scientist am Fraunhofer IML
Evaluating and testing technologies
Technologies can make an important contribution to designing ergonomic workplaces, provided they are used in a targeted manner. Not every technology is suitable for every task, and not every ergonomic challenge can be overcome through technical solutions.
Fraunhofer IML supports companies in selecting, evaluating, and testing suitable technologies. The focus is not on recommending a specific product, but on determining which solution offers the greatest benefit for people, processes, and the work environment. As an independent research institute, we evaluate technologies in a manufacturer-neutral manner and provide a sound basis for decision-making regarding investments and technology implementations.
Our research facilities and laboratories offer a unique infrastructure for not only developing practical logistics solutions but also testing them directly.
Picking Lab
The Fraunhofer IML Picking Lab offers a realistic test environment for modern logistics workstations. Companies can test robotic solutions, order-picking technologies, and digital assistance systems; simulate process variations; and further develop prototypes. This allows innovations to be evaluated early on, investment decisions to be validated, and new technologies to be systematically integrated into operational practice.
Exoskeleton Lab
In the Exoskeleton Lab, Fraunhofer IML evaluates exoskeletons in a manufacturer-neutral manner based on typical logistics processes. We support companies with requirements analysis, system comparisons, and technology selection. In addition, we assist with the development of new prototypes as well as workshops and training – from the selection of suitable systems to their successful implementation in operations.
Designing the ergonomic workplace: Our references
Ergonomic evaluation of a tunnel boring machine
Using the Ergonomics Quick Check, Fraunhofer IML analyzed typical tasks, postures, movements, and environmental conditions on a tunnel boring machine at a depth of 100 meters to assess ergonomic stressors for workers. The results primarily reveal high levels of strain caused by forced postures, confined spaces, and difficult working conditions. Based on these findings, specific improvements were derived in accordance with the STOP principle to specifically support safety, health, and the legally required risk assessment.
Working with IKEA to develop globally applicable ergonomics standard
In collaboration with IKEA, Fraunhofer IML has developed a globally applicable ergonomics standard for central distribution centers. To this end, typical manual intralogistics processes at the Torsvik site were analyzed using measurement sensors, questionnaires, and ergonomic assessment systems. Based on this analysis, concrete recommendations were developed for ergonomic workplace design, the use of technical aids, an international checklist, and a training concept to improve health and safety and efficiency on a global scale.
Augmented reality laser projection at Rhenus
Using the eye-safe augmented reality laser projection system LARS, Fraunhofer IML tested dynamic floor markings for warehouse processes at Rhenus Warehousing Solutions to support employees in the consolidation and preparation of shipments. The field study shows that LARS increases process efficiency and is rated positively by employees in terms of ergonomics, usability, and acceptance, demonstrating that laser-based assistance systems have great potential for human-centered intralogistics.
Designing ergonomic workstations together
Whether it’s ergonomic analysis, technology selection, or testing new solutions, Fraunhofer IML supports companies from the initial analysis through the development of appropriate measures to the successful implementation of new technologies.
Get in touch. Together, we’ll develop solutions for healthy, safe, and productive workplaces.
FAQ: Ergonomic workplace
What is an ergonomic workplace?
An ergonomic workplace is designed to accommodate the abilities and skills of employees. The goal is to reduce physical and mental strain while promoting health, workplace safety, and productivity in equal measures. This approach considers not only work tools and equipment but the entire work system: people, work processes, technology, and the work environment.
Why is ergonomics important for companies?
Ergonomic workstations make an important contribution to health, workplace safety, and productivity. They can reduce physical and mental strain, lower absenteeism, and improve the quality of work. At the same time, ergonomic work design helps companies retain skilled workers in the long term and successfully implement new technologies.
Who is responsible for ensuring an ergonomic workplace?
The responsibility for designing ergonomic workplaces lies with the employer. The basis for this includes the Occupational Safety and Health Act, the Workplace Regulations, and other legal and regulatory requirements. Employees also contribute by using work equipment properly and implementing ergonomic measures in their daily work.
Within companies, occupational safety specialists, company physicians, those responsible for occupational health management (BGM), or health managers – as well as, depending on the organization, the works council – often support the ergonomic design of workstations. Specialized research institutions and ergonomics experts can also be involved in the analysis and optimization process.
What is physical ergonomics?
Physical ergonomics deals with adapting workplaces to people’s physical abilities and limitations. Among other things, it considers body postures, reach zones, movement sequences, and workplace conditions such as lighting and noise. The goal is to reduce musculoskeletal strain and create safe and healthy working conditions.
What is cognitive ergonomics?
Cognitive ergonomics deals with human mental processes – in particular perception, memory, judgment, and information processing – and their significance for the design of work systems and human-machine interactions. Good cognitive ergonomics supports efficient information processing, keeps mental strain at an appropriate level, promotes the acceptance of new technologies, and reduces the risk of erroneous actions.
What is software ergonomics?
Software ergonomics describes the ergonomic design of digital applications and user interfaces. The goal is to develop hardware and software in such a way that they can be used intuitively, efficiently, and safely. This includes, among other things, the design of graphical user interfaces (GUI), usability, user experience (UX), and consideration of human perception and decision-making processes. Good software ergonomics increases acceptance of digital technologies and supports the ergonomic design of modern workplaces.
How is an ergonomic workplace analysis conducted?
An ergonomic workplace analysis serves to systematically identify and evaluate physical and psychological stressors as well as ergonomic potential. In this process, work tasks, workflows, work equipment, and the work environment are considered holistically.
Depending on the specific issues at hand, objective measurement methods, structured observation methods, and employee surveys are used. In addition, digital analysis technologies such as motion capture or Motion-Mining® can be employed, along with evaluations based on ergonomic standards and workplace regulations. The combination of different analytical methods enables a well-founded assessment of the work situation and forms the basis for concrete measures to design ergonomic workplaces that are tailored to human needs.
What is a risk assessment of physical and psychological stressors?
The risk assessment of physical and psychological stressors is a key tool in occupational safety and health. It serves to systematically identify and evaluate work-related hazards and to derive appropriate measures to protect employees.
When assessing physical stressors, factors such as body postures, lifting and carrying, reach zones, and work equipment are taken into account. The assessment of psychological stressors includes, for example, work organization, job content, work tasks, social relationships, the interaction between people and technology, and working environment conditions.
To ensure a thorough assessment, objective measurement methods, structured observation procedures, and employee surveys are combined, depending on the specific issues at hand. The results form the basis for designing ergonomic workstations that are tailored to human needs and help companies promote health, occupational safety, and productivity in a sustainable manner.
What standards apply to ergonomic workstations?
Depending on the specific application, various legal and normative requirements apply to the design of ergonomic workstations. In Germany, these include, among others, the Occupational Safety and Health Act, the Workplace Regulations with its associated Technical Rules for Workplaces (ASR), and ergonomic standards – for example, regarding the design of work systems, reach zones, or software ergonomics. Which regulations are relevant depends on the specific activity, the technologies used, and the work environment.
When is it worthwhile to use exoskeletons?
Exoskeletons can support employees in physically demanding tasks, such as lifting, carrying, or working in forced postures. However, whether an exoskeleton is appropriate always depends on the specific application. Therefore, requirements, work processes, and operating conditions should first be systematically analyzed. A manufacturer-neutral evaluation and testing process helps companies select suitable systems, make informed investment decisions, and integrate exoskeletons into daily work routines in a targeted manner.