Ergonomics: Designing Safer, More Productive Workplaces — Guide & Best Practices
Ergonomics: Designing Safer, More Productive Workplaces — Guide & Best Practices
Ergonomics—also known as human factors engineering—focuses on designing workplaces, equipment, and systems that fit the people who use them. Effective ergonomics reduces workplace injuries, improves operational efficiency, and enhances employee well-being. By understanding human physical and cognitive capabilities and limitations, designers can create systems that optimize the reception, processing, and interpretation of information while accounting for environmental constraints.
Ergonomics (engineering psychology or human factors engineering) is the applied science of designing products, tasks, environments and systems for human use. The field centers on achieving an optimal man–machine fit and centers on several primary objectives:
Achieving man–machine fit so equipment and tasks match human abilities.
Reducing industrial accidents through safer designs.
Ergonomics: Designing Safer, More Productive Workplaces — Guide & Best Practices
Why Ergonomics Matters
When equipment or workstations force workers to adapt in ways that exceed their capabilities, the result can be fatigue, pain, errors, reduced productivity, and higher accident rates. Proper ergonomic design reduces musculoskeletal injuries (e.g., strains, cramps), visual fatigue (eye strain, headaches), and cognitive overload while improving accuracy and decision-making.
History and Evolution of Ergonomic Design
Before the mid-20th century, engineers often designed machines and processes without extensive consideration of operator needs. Workers had to adapt to machines—often with negative consequences for health and performance. The increasing complexity of machines during World War II, as well as early time-and-motion studies by Frederick Taylor and the Gilbreths, highlighted the need to design systems that adapt to people rather than forcing people to adapt to systems. This shift laid the foundation for modern ergonomics: designing equipment and workplaces that accommodate human physiological and cognitive strengths and limitations.
Designing Work for People: Principles and Practices
Good ergonomic design begins with a human-centered approach. Key considerations include:
Fit the task to the person: Adapt tools, controls, and workspaces to the range of worker sizes, abilities, and reach.
Reduce repetitive strain: Rotate tasks, incorporate micro-breaks, and redesign tasks to minimize repetitive motions.
Optimize posture and support: Provide adjustable seating, correct table heights and footrests when needed to maintain neutral body posture.
Minimize force and awkward movements: Use mechanical assists and tools to reduce excessive force or non-neutral joint positions.
Design for cognitive load: Present information clearly, reduce unnecessary complexity, and support decision-making with timely feedback.
Account for environment: Lighting, noise, temperature, and vibration all affect comfort and performance—design or control environmental factors accordingly.
Types and Characteristics of Technology Relevant to Ergonomics
Modern technology influences ergonomics in two broad ways:
Machine technology (physical): Equipment, layout, and hardware such as manufacturing machines, workstations, ergonomic chairs, and advanced manufacturing tools.
Knowledge technology (procedural/software): Methods, systems, and information-processing tools including software interfaces, workflows, and decision-support systems.
Common technology applications that intersect with ergonomic design:
Advanced manufacturing technology (ATM) and computer-aided engineering (CAE) that change how tasks are performed and may reduce physical strain.
Information and communication technologies (ICTs) for capturing, storing and sharing information; these must be designed with user interfaces that minimize cognitive workload.
Service-oriented technologies that alter job tasks and human-system interactions, affecting both physical and mental workload.
Factors to Consider When Designing Controls
Controls are the tactile and operational elements people use to interact with machines and systems. Good control design should consider:
Location and reach: Controls should be within comfortable reach for the anticipated user population.
Size and shape: Controls must be sized and shaped to be used accurately and safely (e.g., knobs, levers, buttons).
Force and travel: Required operating force and travel distance should match users’ capabilities and task demands.
Feedback and confirmation: Controls should provide clear tactile, visual, or audible feedback to confirm actions.
Consistency: Similar controls should operate in consistent ways across devices and systems.
Safety and protection: Place emergency and high-risk controls to prevent accidental activation while ensuring accessibility when needed.
Factors to Consider When Designing Displays
Displays present information and therefore drive perception and decision-making. Display design should address:
Visibility and legibility: Use appropriate font sizes, contrast, color choices, and lighting controls so information is readable in expected conditions.
Information hierarchy: Prioritize critical information visually so users can rapidly scan and identify what matters.
Clarity and simplicity: Avoid clutter; present data in meaningful units and avoid unnecessary complexity.
Mapping and layout: Arrange displays so relationships between controls and information are intuitive.
Multimodal feedback: Complement visual displays with auditory or haptic feedback where appropriate to reduce overload.
Error prevention and recovery: Design displays that reduce misinterpretation and clearly guide operators through corrective actions when needed.
The New Face of Work: Technology, Automation, and Human Roles
The 21st century workplace is becoming increasingly automated. Automation and digitalization change the nature of many jobs, shifting work from manual tasks toward monitoring, decision-making and supervision of systems. Ergonomics must evolve to address:
Cognitive ergonomics: With automation, human roles often become supervisory. Designers must guard against vigilance decrement, complacency, and loss of situation awareness.
Human–automation teaming: Ensure clear role boundaries, explainable automation behaviors, and appropriate levels of automation so humans remain in the loop when necessary.
Remote and hybrid work: Office ergonomics in home environments—seating, display height, input devices and lighting—now play a larger role as more employees work remotely.
Inclusive design: Technology should accommodate users with a wide range of physical abilities, ages and cultural expectations.
Practical Steps to Apply Ergonomics in the Workplace
Conduct ergonomic assessments: Use task analysis, anthropometric data and employee feedback to identify risk areas.
Implement adjustable solutions: Provide adjustable chairs, desks and input devices to suit a range of users.
Train employees: Teach safe postures, proper use of equipment and micro-break techniques to reduce strain.
Use participatory design: Involve end users in design decisions to capture real-world usage and preferences.
Monitor outcomes: Track injury rates, productivity metrics and employee satisfaction after ergonomic interventions.
Iterate and improve: Ergonomic solutions should be tested and refined based on performance data and ongoing feedback.
Conclusion
Ergonomics is a vital discipline that blends engineering, psychology and design to create safer, healthier and more productive workplaces. By understanding human capabilities and designing controls, displays and work systems to match those capabilities—especially in an era of rapid technological change—organizations can reduce accidents, improve performance and enhance worker well-being. Whether you manage a factory floor, a control room, or a remote office, investing in ergonomic design is an investment in people and performance.
Further reading and resources
International Ergonomics Association (IEA) — ergonomic principles and standards