Sustainable Efficiency Through Ergonomic Design and Optimization of Assembly Workstations

The paper focuses on exploring ways to achieve sustainability in the manufacturing process through targeted optimization and ergonomic improvements of the work environment. The introductory section emphasizes the importance of sustainability from the perspectives of worker well-being, occupational safety, and efficient resource utilization. The paper presents a digital approach to workstation design with an emphasis on sustainability, which includes the creation of a 3D model of the assembly station using SolidWorks (v.2017) and Jack software (v.8.3), where the work movements of a virtual mannequin with realistic parameters are simulated. The analytical section is dedicated to evaluating workstation ergonomics using the RULA (Rapid Upper Limb Assessment), SSP (Static Strength Prediction), OWAS (Ovako Working Posture Analysis), and Lower Back Analysis methods, with the aim of identifying operations that reduce the sustainability of the work process due to excessive physical strain. Badly designed operations have a negative impact on sustainability in the meaning of physical workload strain (social dimension), low effectivity and quality (economic dimension), and higher resource (material, energy, transport, etc.) usage (environmental dimension). All these dimensions can be measured and expressed by number, but this paper focuses on workload only. Based on the results, specific measures were proposed with a focus on sustainability—raising the working height of pallets, optimizing the positioning of tools, and adjusting work movements. Repeated analyses after the implementation of these changes confirmed not only a reduction in physical strain and increased safety but also the enhancement of the sustainability of the working environment and processes. The results of the article clearly demonstrate that digital simulation and ergonomic design, oriented toward sustainability, are of crucial importance for the long-term efficiency and sustainable development of manufacturing organizations. The novelty of the work is in contribution to empirical validation on the role of digital twins, virtual ergonomics, and human factors in Industry 5.0 contexts, where the synergy between technological efficiency and human-centric sustainability is increasingly emphasized. The proposed approach represents a practical model for further initiatives aimed at improving the sustainability of assembly workstations.