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Design of an assembly workplace for an employee with back illness


The employer is a manufacturer of garden machinery.

Disability and functional limitation of the employee:

The severely disabled man suffered from a private accident a traumatic brain injury that resulted in a brain contusion or brain contusion and a spinal injury. Due to the traumatic brain injury leads to neurological disorders in the hands and legs and the spine damage to functional limitations in standing and walking. The man should avoid the frequent lifting and carrying of loads and taking certain postures (stooping and standing for long periods).


The man has worked as a production assistant in the assembly.

Workplace and duties (actual status):

The production assistants mounted knife in the cutting heads of garden shredding. To this end, he takes the 10 kg heavy cutting heads from a lattice box standing on the floor, picks it up a work table and screwed the knife firmly provisional. The pre-assembled parts are then placed on a wooden pallet on the ground with 20 units or temporarily stored and then transported with a pallet jack 5 meters to another work table. He takes the cutting head of the stationary pallet on the floor, and places it in a fixture to align the blades. The pre-aligned and bolted assemblies are stored for later assembly in total more grid boxes standing on the floor. Disability Due give him the predominantly standing executed assembly sequence, except for the alignment of the blade while sitting and frequent bending and carrying of loads big trouble.

Workplace and duties (desired status):

Both jobs are combined into one. At a height-adjustable work table is the mounting device for knife-direction and the Storage bin with the knives that are provided by other employees in the workplace. The cutting heads are next to the work table in a grid box on a lifting and tilting device, with the aid of the grid box can be positioned ergonomically for the removal of the cutting heads in grasping space. To remove the knife from the front storage box production assistant wearing a cut-resistant glove. The cutting heads and the knives are placed directly into the fixture, aligned and mounted. The completed assemblies are then placed in a grid on another lifting and tilting device and can be removed with this at any time. With a stand-up seat as a support aid the production assistants may at any time choose between a stand-seated or standing posture. In addition, a cushioning and non-slip work mat was transferred to additionally relieve the spine when standing on the ground.
Through workplace design the transport and the handling of loads from ergonomically unfavorable positions and redundant work processes are avoided. The production assistant is a durable and stress-free work permits

Assistive devices used:

stools and standing chairs
workplace mats
lifting and positioning systems
tools for fixing and positioning of workpieces and tools (storage boxes)


Workplace design was sponsored by the Office integration.
In REHADAT you will also find the addresses and telephone numbers of the Integration Office.



  • physical disability /
  • organisation /
  • worktable /
  • table /
  • lifting device /
  • lifting aid /
  • positioning aid /
  • working equipment /
  • standing seat /
  • seat /
  • standing aid /
  • pallet /
  • view storage box /
  • safety /
  • protective clothing /
  • tilting device /
  • skeleton container /
  • container /
  • storage box /
  • prevention of accidents /
  • risk of accident /
  • gloves /
  • safety gloves /
  • mat /
  • work task /
  • handling /
  • assembler /
  • production assistant /
  • assistance /
  • employment /
  • participation in working life /
  • participation /
  • full-time job /
  • employer /
  • employee /
  • vocational rehabilitation /
  • brain /
  • spine /
  • personal protection equipment /
  • material /
  • handling and transport /
  • body posture and body part movement /
  • mobility and locomotion /
  • environmental influences, safety and loads /
  • brain damage /
  • office for vocational integration /
  • motor impairment /
  • back illness /
  • head trauma /
  • production /
  • industry /
  • fitting /
  • body posture /
  • standing /
  • walking /
  • lifting /
  • carrying /
  • motoricity /
  • coordination of movements /
  • finger hand movement /
  • body load /
  • bending /
  • workplace design /
  • work organisation /
  • industrial safety /
  • technical advice /
  • assistive product

update status: 05.02.2010

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