Fitting the task to the human: rethinking ergonomics in manufacturing

As Cecilia puts it, “Manufacturing is ever evolving,” and with that evolution comes a steady stream of new technologies aimed at improving the operator experience at large. However, with each innovation, it is essential to truly consider how operators interact with and are affected by the technology. That is why user interface and user experience should play a crucial role in design. Ergonomics is not just about physical comfort, it involves adopting a broader perspective on human well-being that includes both cognitive and physical factors.

Wearable technology and collaborative robots are opening new possibilities in the field of ergonomics. Devices that track posture, monitor physiological signals like heart rate and temperature, or support the body through exoskeletons are becoming increasingly common on the factory floor. These tools help us better understand how work impacts operators, both physically and cognitively. Cobots, or collaborative robots, also play a role by taking over dull, dirty, and dangerous tasks, reducing physical strain and allowing humans to focus on less repetitive, more value-adding activities. In this way, ergonomics becomes more than just a matter of comfort, it becomes a means of extending human capability in demanding environments.

But to truly design for operator well-being, we need to understand what people are experiencing. As Maciej puts it, “Data is the new gold in the industry,” and collecting data on ergonomic conditions is essential for knowing where to focus, how to improve, and what to prioritize in both tool development and workflow design. Of course, data alone is not enough. It has to be presented in a way that is clear and actionable. That means designing intuitive interfaces and training people not only in how to use the technology, but also in how to interpret the information they receive. If the purpose isn’t clear or the tools feel intrusive, operators could potentialy ignore them or find workarounds, which ultimately undermines their intended value.

Taking a long-term view is essential when making the business case for ergonomics. With changing demographics, including an aging workforce and a push to make manufacturing more inclusive for women, investing in ergonomics is not just a cost, it’s an investment in people, technology, and safer, more sustainable working conditions. By addressing all elements of the equation, companies benefit from higher quality output, more engaged employees, and reduced risks of injuries and illnesses. Ergonomics also drives productivity and efficiency by removing guesswork. Instead of wondering whether a task was done correctly or if fatigue affected performance, data and thoughtful design provide clear answers.

Adopting this long-term perspective doesn’t always have to mean expensive overhauls. Sometimes, simple adjustments, like rebalancing a production line to better suit operator needs or optimizing existing equipment, can make a significant difference. Catering to specific ergonomic needs, such as providing better lighting to compensate for age-related vision changes or designing lighter tools that require less force, helps retain valuable workers and supports diversity on the factory floor. These thoughtful improvements not only reduce the risk of a brain drain from an aging workforce but also make manufacturing environments more inclusive and productive for everyone.

As Frida reminds us, “It can be small changes” that make a big difference when it comes to ergonomic improvements. At Atlas Copco, close collaboration with operators and real-world manufacturing environments is key. Understanding how products are actually used,often different from initial assumptions, helps ensure that design decisions truly meet user needs. Part of this involves carefully considering how data is presented, making sure the right information reaches the right person at the right time without overwhelming them.

Regular visits to customers allow us to observe the full context, including factors like lighting and noise, that can affect operator well-being. Keeping humans at the center, we focus on human-centric design. For example, after reviewing a customer’s application, we realized a prototype battery was too large for their ergonomic needs and developed a smaller version to better align with their work. Small considerations like this, can make big impacts.