The First Facility Management Blog

This Web Exclusive comes from James Anderson, vertical market manager for Holliston, MA-based Lista International.

Purchasing a workbench or workstation may at first seem like a simple task. Your employees have work to do, and they need an efficient, comfortable, and practical place to do it. But behind that deceptively simple proposition may lurk a number of variables that must be considered to make sure you get what you actually need.

Employee needs vary widely among industries and applications. What’s perfect for an automotive dealership won’t work in a laboratory. What works for manufacturing facilities just won’t fly for a classroom setting. And a configuration that suits one laboratory may not be appropriate for another.

So, whether you are looking for technical workstations, height adjustable workstations, assembly workstations, industrial benches, packing and shipping benches, or accessory systems, take the time to perform the necessary research upfront by following this step-by-step self examination that will help you choose the right workbench for all your needs.

The number one consideration – what work are you doing on the bench?
The answer to this question will affect everything from the size of the workbench to the surface material, to storage requirements, to ergonomic considerations.

Once you determine what work will be performed on the bench, conduct an analysis of tasks associated with the work and use it to make a checklist of features needed to perform them. For example, say you’re in the business of assembling and maintaining cell phones, and you need to furnish a workspace for your repair technicians. You want a small workbench, perhaps one that is height adjustable, to bring the detailed repair job up to an optimal work zone and distance. Along with the workbench, you will also need an excellent lighting accessory. You’ll likely also need bins above the work surface to provide direct access to small parts, and an articulating arm that can hold assembly guidelines or diagrams. And depending on the flow of your repair operations, you might want to consider a material transfer work surface, or even a conveyor workstation, both of which can cost effectively expedite material handling.

Or maybe you’re working in a pharmaceutical lab where the work surface material becomes a more important part of the decision. Depending on the liquids and solids you’re handling, you might want either a stainless steel or epoxy resin chemical resistant work surface to ensure long lasting, durable use. If your laboratory is in a clean room environment, your workstation will need to meet certain NSF International public health and safety standards. You might also need to store a combination of small beakers and instruments with large testing equipment—requiring a variety of storage solutions both above and below the work surface.

For example, Bob Smith, production manager for Automated Circuit Design (ACD), said, “All the workstations are electro-static dissipative, so they are an ideal solution for every department. In the kitting area, technicians can safely work with ESD sensitive components. And in the assembly and production departments, every technician can perform the most precise processes effectively. The workstation provides the lighting needed to perform every task with attention to every detail. Additionally, the substantial shelving space offers the area needed to set up stations for testing completed products.”

Sizing up the solution
The size of your workbench is determined by a number of factors. First up is how much space is available in the work environment – how big a footprint will it occupy? With today’s modular workbenches making maximum use of vertical space, you may not need as big a workbench as you think.

Next, how much work surface area does your application demand, both in terms of width (left to right) and depth (front to back)? Does the entire work surface need to be within easy arm’s reach (by, say, an assembly technician)? Can you position needed items above the work surface on a vertical accessory system for easier access? Will you be working with large equipment or parts? If so, you may not only need a larger work surface, but might also need to factor in the weight bearing capacity of your workbench.

Workstation meets workflow
After thinking about size and footprint, you should consider whether your company’s workspace, type of work, and workflow are best served by a group of workstations laid out in a particular configuration. Some companies offer modular workstations that are specifically designed to accommodate different configurations and different types of workflow. Use a design that positions your team for maximum efficiency.

If you’re operating with a progressive workflow, you may want to configure your workbenches to create an integrated, moving production line. Flow racks can then be used to stage and deliver parts using gravity, reducing material handling time, point of use storage, and cost.

If your team functions in cells or groups, it may be served best by different shaped configurations that encourage easy communication. Some workstations are available in modules, so they can easily be combined to create everything from in-line and in-line back-to-back configurations to T, U, X and Y-shaped configurations.

Finally, consider transforming from stationery to mobile workbenches. Effortlessly accomplished with mobility enhancing accessories, mobile workbenches can provide for easy, smooth rolling relocation. This will accommodate both day-to-day and future changes as well as simplify cleaning activities.

Storage – everything in its place and a place for everything
Spend some time doing some careful planning to get a workstation that exactly addresses your storage needs with little or no wasted space. Simplify your storage decisions by reducing the items being stored to only those that directly address your workbench applications. When doing your planning exercise, consider the size, shape, weight, quantity, and fragility of the items to be stored, as well as how accessible they need to be and how much security they demand.

Do you need a home for shipping documents? A bar code scanner? Test equipment? Small parts? Tools? There are plenty of options for storage, both above and below the work surface. From plastic parts bins to a variety of shelving options to every size and configuration of drawer, there’s a lot to consider.

After determining exactly what needs to be stored, zero in on making the workspace more efficient. Create a designated storage location for every item. Modular drawer cabinet interiors are ideal for custom configuring to produce almost infinite layout options. This high level of organization is particularly important if different people are using the same workbench at different times. Time savings are maximized and inventory control becomes a non-issue.

Let there be light
Lighting needs of the different workbench tasks is an important consideration. Does each station need separate lighting? Does the room itself have lighting deficiencies? Does the room light cast an unwanted color? And if you decide you need to equip your workbenches with lighting accessories, are your technicians best served by overhead fluorescent lighting or a swing arm that can be easily positioned and/or moved out of the way when not needed? Do you need an accessory that can diffuse the light and reduce glare?

Power to your people
After you weigh your lighting needs and options, you should next move on to your electrical requirements. From clean rooms to quality control departments to research and development functions, a convenient source of power at each workbench can be essential. There are diverse options to consider—from power beams and air beams to air supply brackets and cable management accessories. You can narrow your selections down to the necessary few by asking the right questions:

First consider the applications. Will each workbench be home to a computer monitor and other computer equipment? Do you need a data beam? Will the tasks at hand require compressed air, and what is the source of that air?

How many outlets do you need at each workbench (and how much power)? Where should the outlets be positioned? Do you require a ground fault circuit interrupter (GFCI) to provide protection against severe shock and electrocution? Consider cord management, both from an aesthetic point of view, as well as the safety factor. To keep power cords from becoming tripwires, cable trays may be needed.

The right accessories make the space more efficient
Think about the impact that add-on accessories might have in improving the employees’ job functions. No matter what the task, there’s an accessory option to help get the job done more efficiently and conveniently. By taking advantage of the abundant vertical space above the work surface, and the many interchangeable accessory options available, you can create a highly efficient work center that is tailored completely to the needs inherent to jobs being performed in the workspace. Examples include shelving for manuals or instruments, parts bin rails, a monitor bracket, or a keyboard holder.

Pay attention to ergonomics for safety and productivity
It is essential to factor in ergonomics to improve safety and productivity. To minimize stress and strain for seated employees, a 30.5″ work surface height will accommodate 99.5% of all male and 99.9% of all female workers. The optimal work surface height for standing employees depends entirely on the type of work being performed. Precision work usually requires a higher work surface, while heavier work demands a lower work surface.

But what if different shifts are using the same bench? And/or what if different tasks are being performed on the same bench? If so, consider an adjustable height workstation. With such a bench, users can adjust the bench height with the simple turn of a crank or with a motor drive, and the work surface can move between approximately 25 and 41″.

Standardization leads to improved adaptability
Most companies have multiple departments, from manufacturing to testing to shipping. Consider using a common workbench platform throughout the facility to gain such benefits as better utilization of inventory, easier reconfiguration, interchangeability of accessories, and aesthetic appeal.

Standardization allows efficient swapping of accessories among departments, and facilitates adjustments if work tasks change. Colors and designs match, and there are no surprises when employees shift to a different department.

Design standardization (and an attractive price point) is important, but the quality and durability of the workbenches and other furniture was also a key consideration. “Schools are a very hard environment for furniture, especially where students are constantly using the table to perform different tasks,” notes <!– @page { margin: 0.79in } P { margin-bottom: 0.08in } –>Tom Buechele, associate vice president of facilities, operations and planning at the School of the Art Institute of Chicago (SAIC).

Putting it together with design assistance
If this list of considerations poses questions for which you need help to find answers, maybe you’d prefer to have help with your quest for the perfect workbench. Many workbench providers offer design planning assistance to guide you through the process and advise you of the most appropriate choices. Free services such as surveys and CAD drawings can make the process virtually painless.

If you choose a workbench provider who offers maximum breadth of product and flexibility, you’ll be able to view all of your workbenches as part of a complete picture, although each may have been custom built to accomplish a unique task. The end result? Many smart steps for each department and one giant leap for your business.

It can be difficult to start conversation among strangers, which is why RCA designer Thomas Urban Gardner has done his best to help “break the ice.” His unusual invention, the DeLighTable, incorporates pressure sensitive material and waterproofed electronics (which run on 12 volts of power), to transform boring tabletops into a palette of ultimate grooviness.

Ideal for bars, restaurants, and nightclubs, the surface illuminates when any glass object placed on it. People can draw or write a message on it, which fades away in seconds. DeLighTable can be ordered in the following formats: Coffee Table, Dining Table, Standing Table, Table Top Panel or Shelf Panel (custom inquiries are also welcome).

Casulo, a new concept for mobile living originated in June 2007 as a part of the dissertation of Marcel Krings and Sebastian Mühlhäuser at the Köln International School of Design in Cologne. So what is it? Pictured at left, it’s a complete furniture set which can be set up in less than 10 minutes and later disassembled and repacked like a standard pallet. No tools are needed in the process.

A packed Casulo can be transported and stored at nominal expense by any carrier and shipping agent. Not only can a disassembled Casulo unit be packed with one’s personal items, the Casulo itself is sturdy and thus no additional packaging materials are necessary when it is ready for transport.

The Casulo can then either be sent to a prearranged address or delivered directly. Two people can lift, carry, and assemble each piece of furniture within the Casulo. The unit is constructed of durable, long lasting materials.

Each Casulo unit includes all the essential furniture for setting up in a new place: wardrobe, large desk/table with a separate desk cabinet with locking drawers, a revolving, height adjustable desk chair, two stools, a single bed and mattress, and a tall set of shelves. The stools and the drawers of the desk cabinet also serve and double as additional storage containers.

When disassembled and packed, the Casulo becomes a crate. It can even fit in the trunk of a medium sized vehicle.

When the furniture has been disassembled and prepared for transport, the Casulo is safe and sturdy; additional packing materials are not required. An additional feature of the Casulo is that when packed, half of its volume becomes space for storage and at least 440 pounds can be safely placed atop it. See the video below.

A variety of features makes each unit an innovative solution–particularly when temporary living space or student housing is necessary: there are invisible locks on the desk drawers; a magnetised clothes rack system; and safeguards for computer cables and electric wires. The Casulo ideal for those in job training, students, and people in the service industry who have to change their location frequently. People who must move frequently and rent empty rooms need no longer accumulate sets of inexpensive furnishings whose transportation costs are higher than the value of the furniture.

Still in its prototype stage, Casulo’s designers look forward to going into production as soon as possible. For more information, visit this link.

Incheon Metropolitan City, Korea, together with designboom recently held a competition (iida) open to international professionals, students, and design enthusiasts. The subject of iida was “Green Life,” which was broken down into the following concepts:

• 21st century design is the philosophy that suggests harmony of humanity and nature.
• 21st century design is the imagination that enables sustained urban life.
• 21st century design is actions that buffer radical changes in society.
• 21st century design is a beautiful link between business activities and consumer activities.
• 21st century design is a tool that expresses beautiful imagination of people.
• the philosophy of the 21st century design is the philosophy of iida.

In the end, 3709 designers from 96 different countries participated. Rochus Jacob was awarded the first prize for his Murakami Chair (along with his thermodynamic cooler), which incorporates nano-dynamo technology into the skids of the chair to run an OLED light—thereby powering an attached reading lamp with energy generated from its own rocking motion. (Note: as one of the competition requirements, the product could not currently be in production.)

Jacobs explains his thoughts behind the design process:

I was looking for opportunities to generate energy through activities we naturally do. The final result is a rocking chair that enables the user to experience production and consumption of electricity in a gentle and rewarding way. An abstract process becomes tangible and eventually cultivates natural awareness. Complexity is covered by simplicity. During daylight, the energy gets stored in a battery pack. The construction of the flat and bendable organic light emitting diodes allows new form factors such as using the traditional shape of a lamp but instead of having a light bulb the lampshade himself turns out to be the light source. To have a drastic reduction of consumption the big challenge will be to make consuming less feel like getting more.

The jury, composed of Julien de Smedt, JDS, architect, Karim Rashid, industrial designer, Jerszy Seymour, industrial designer, Martin Videgård Hansson + Bolle Tham, Tham & Videgård Hansson Architects, Birgit Lohmann, designboom, Sang-Soo Ahn, Hongik University visual communication design professor, Soon-Jong Lee, Seoul National University design major professor, Joo-Yun Kim, Hongik University industrial design professor, Chul-Bae Lee, LG eletronics vice president, and Heung-Soo Jeon, Incheon Metropolitan City design manager awarded designs and concepts that were deemed innovative in terms of their formal/technological aspects as well as their social relevance.

The competition was hosted by Incheon Metropolitan City and organized by Incheon Business Agency.
Sponsors of this competition are: Ministry of Knowledge Economy of Korea, Korea Institute of Design Promotion, LG electronics, designflux, Incheon Industrial Design Association, and Incheon Design Company Association.

When Boston-based designer Justine Sterling, of Justine Sterling Design, was nearing the completion of a recent expansion project for her client, the Greater Boston Food Bank (GBFB), she realized the non-profit was hitting its budget limit on the new warehouse and distribution facility with little remaining to adequately furnish the modest space allocated for the organization’s management office.

In looking for a solution, Sterling turned to colleague, Amy Hill, an Allsteel Architecture & Design Specialist, who saw this as an opportunity to repurpose Allsteel furnishings that had been used for local trade show displays.

Now complete, the Food Bank, which distributes approximately 30 million pounds of food annually has its reception, office, and conference room areas furnished with Allsteel chairs and tables.

“Building a new facility was a daunting task, and most of our financial 
resources were used for the warehouse, equipment, and racking,” said Kathleen Marre, chief administrative officer for GBFB. “Our office furniture budget was very minimal. Without the donation from Allsteel, much of our space would have gone empty. Our employees work very hard, and providing them with such beautiful furniture really improves our working environment.”

Allsteel and its Boston-based team were pleased to know the donation had such an impact. “The Greater Boston Food Bank provides such an important service to the community,” said Hill. “So, we’re proud to know we’re helping them in their work and, at the same time doing our part toward an Allsteel initiative to reuse and repurpose our furniture.”

Read TFM’s June 2009 coverage of furniture reuse and recycling, “Avoiding The Landfill”.