Supporting Ergonomics from Concept to Implementation

Whether you’re designing a new product, updating a manufacturing process, or selecting new equipment, our experts provide ergonomic design evaluations that ensure human performance, safety, and efficiency are built in from the very beginning.

By addressing ergonomics early in the design lifecycle, organizations can significantly reduce the risk of musculoskeletal disorders (MSDs), prevent costly redesigns, and improve long-term productivity.

What We Evaluate

Our evaluations focus on the critical interaction between the worker and the system. Depending on your needs, this may include:

• Operator fit and reach
• Posture and body mechanics
• Required forces and exertions
• Repetition and task frequency
• Visual, cognitive, and control demands
• Interface layout and usability
• Tool and equipment accessibility
• Material handling requirements
• Maintenance and service access

Product Design Evaluations

For new or updated products, we evaluate usability, physical compatibility, and user interaction to minimize risk and maximize performance.

• Assessment of grip, force, and control layout
• Evaluation of user posture and reach requirements
• Identification of high-risk use conditions
• Recommendations to improve comfort, safety, and efficiency
• Support for prototype reviews and pre-production testing

Process Design Evaluations

When processes are redesigned or newly implemented, our team evaluates task flow, workstation layout, and movement patterns to ensure ergonomic risk is minimized while productivity is optimized.

• Task sequence and work flow review
• Identification of bottlenecks and high-exposure tasks
• Evaluation of manual material handling
• Optimization of work heights, reach zones, and spacing
• Recommendations aligned with lean and continuous improvement goals

Equipment Selection & Design Evaluations

Selecting the right equipment has long-term implications for worker safety and business performance. We provide objective evaluations of new or proposed equipment to ensure it fits both the task and the worker.

• Operator access and posture
• Force and repetition requirements
• Adjustability and accommodation of user variability
• Control layout and visibility
• Maintenance and cleaning accessibility
• Compatibility with existing workflows

Evaluation Methods & Tools

Our ergonomists use a variety of proven tools and scientific methods to evaluate design risk, including:

• Anthropometric and reach modeling
• Postural and biomechanical analysis
• Force and repetition assessment
• Task and time-motion studies
• Cognitive and usability evaluations
• Risk-based screening and prioritization tools

Deliverables You Can Use

Each design evaluation includes practical, decision-ready outputs to support engineering and leadership teams.

• Risk identification and prioritization
• Practical, cost-conscious design recommendations
• Visual documentation (photos, diagrams, or models) when applicable
• Alignment with production, quality, and budget goals
• Clear documentation for due diligence and design justification

Key Benefits of Ergonomic Design Evaluations

• Reduced injury and MSD risk
• Improved usability and operator performance
• Lower redesign and retrofit costs
• Better product quality and consistency
• Stronger worker acceptance and engagement
• Improved compliance and defensibility

Who This Service Is For

• Product designers and developers
• Manufacturing and process engineers
• Industrial engineers
• EHS and safety teams
• Operations leadership
• Maintenance and reliability teams
• Procurement and capital projects teams

How This Service Integrates with Other Ergonomics Programs

Product, Process, and Equipment Design Evaluations integrate seamlessly with Engineering Guidelines and Checklists, Industrial Evaluations, Solutions Pilot Testing, Continuous Improvement Events, and Ergonomics Program Development to create a full life-cycle ergonomics strategy—from design through operation.