Ergonomics and automation in the small parcel process
Workstations were redesigned around work-to-operator principles. Automatic box closure was implemented, and ergonomic improvements were measured and validated.
Cause
Peak workload
Work location
Hybrid
Approach
2 phases
Johnson Controls International operates complex production environments across multiple countries. At its site in Enschede, the small parcel department came under pressure during peak periods, while the workstation layout was not set up for efficient and ergonomic handling.
The core issue was simple: operators were moving to the work instead of the work coming to them. Solving that required changes to workstation design, material flow and equipment.
The challenge
The department needed an on-site analysis of ergonomics, process flow and workstation design, followed by a practical improvement concept that could actually be implemented. That mix of process expertise and hands-on technical knowledge was not available internally.
Blackbear's role
Blackbear helped define the assignment clearly from the start and engaged a specialist who could combine time and motion studies, workstation redesign and equipment integration. Getting that profile on site quickly made the difference between a theoretical recommendation and a working solution.
Result
Workstations were reconfigured around work-to-operator principles, automatic box closure became operational and ergonomic improvements were measured and documented. Material flow was redesigned to reduce unnecessary movement and improve throughput.
