Ergonomics and automation in the small parcel process

Johnson Controls is a global leader in building management systems and industrial solutions, operating across dozens of countries with complex on-the-floor processes. At its facility in Enschede, the Small Parcel department was coming under increasing pressure during peak periods, and the workstation layout was not built to handle it efficiently or ergonomically.

The core issue was deceptively straightforward: operators were moving to the work rather than the work coming to them. In practice, addressing that means touching workstation layouts, material flows, equipment, and established habits all at once.

The challenge
The department needed a thorough on-site analysis, covering ergonomics, process flow, and workstation design, followed by a practical improvement concept that could actually be put into operation. The combination of process expertise and hands-on technical knowledge required was not available internally.

Blackbear's role
The scope of the assignment was defined clearly from the outset, with Blackbear identifying the specific profile needed: a specialist capable of conducting time and motion studies, redesigning workstations, and overseeing the integration of new equipment. Finding that combination in a single professional, and getting them on site quickly, made the difference between a standing recommendation and a working solution.

Result
Workstations have been reconfigured around work-to-operator principles, automatic box closure is fully operational, and ergonomic improvements have been measured and documented. Material flow has been redesigned to reduce unnecessary operator movement, with measurable gains in throughput efficiency across the department.