Workstation redesign for a repetitive drill press operation: A combined work design and ergonomics approach

A typical or conventional workstation for a repetitive drill press operation was evaluated and subsequently redesigned by incorporating the concepts and principles of work design and ergonomics. The production task comprised of drilling four holes on a prepared steel plate. A methods–time measurement (MTM) analysis was conducted to eliminate unnecessary motions and improve the necessary (work) motions involved in task performance. The specific features of the redesigned workstation were specially designed equipment (jig, fixture, etc.), a suitable adjustable chair, proper work height, a placement of tools/equipment within reach envelope, and a comprehensive operator training method. An experimental investigation was conducted to evaluate and test the redesigned workstation in terms of operator productivity (production quantity and quality output) and satisfaction. The increases in quantity (number of holes drilled) and quality (number of good holes drilled) output were 22 and 50%, respectively, for the redesigned workstation compared to the typical or conventional workstation. The high improvement in quality output (50%) could be attributed to the improved design of the jig and fixture and the comprehensive operator training method, which emphasizes the quality aspect of production output. The improvement in operator satisfaction (scores) were highly significant. This investigation has demonstrated the beneficial effect of a combined work design and ergonomics approach, especially for the redesign of a workstation for a repetitive drill press operation. © 2007 Wiley Periodicals, Inc. Hum Factors Man 17: 395–410, 2007.