Ergonomic and Automation Based Process Redesign in Industrial Workstations

Industrial workstations play a critical role in determining productivity, worker safety, and overall operational efficiency. Traditional workstation designs often rely on manual processes and fixed layouts, which can lead to musculoskeletal disorders, operator fatigue, and inconsistent production performance. With the increasing demand for high precision manufacturing and sustainable industrial practices, integrating ergonomics with automation has become essential. This paper presents an ergonomic and automation based process redesign framework for industrial workstations aimed at improving worker comfort, reducing physical strain, and enhancing productivity. The proposed approach combines ergonomic risk assessment, task analysis, and selective automation using sensors and control systems. A comparative analysis of pre and post redesign workstation performance is discussed, highlighting improvements in cycle time, error reduction, and worker well being. The results demonstrate that ergonomics driven automation can achieve both human centric and performance oriented manufacturing objectives.