Ergonomic Workstations at 65% Less Cost

Client: Aldes — ventilation & airflow products manufacturer, 50+ employees · Sector: HVAC manufacturing · Result: −65% workstation cost, ergonomic strain fixed

The challenge: growing demand, straining workers, costly benches

After moving to a new facility to meet rising market demand, Aldes needed to modernise its production equipment. At pre-assembly, workers using overhead power drills were developing arm and shoulder strain from lifting the tools all day — and conventional custom workbenches to fix the problem were quoted at prices the project couldn't carry.

The solution: employee-designed modular workstations

The facility's continuous-improvement leader introduced the Flexpipe tube and joint system and put the design pencil in the workers' hands. The people doing the job designed benches around their own tasks:

• Tool balancers mounted on overhead modular rails — drills now hang at hand height
• Bench dimensions matched to each operator's reach and the parts being assembled
• Components reused for other structures as the line evolves — nothing is single-purpose

The results

• New workstation cost reduced by 65% versus conventional equipment
• Ergonomic strain at pre-assembly eliminated
• Employee-led design became standard practice for line changes

What this means for Australian manufacturers

WHS obligations around manual handling are stricter in Australia than almost anywhere — and ergonomic injuries are among the costliest claims. Modular workstations fix the strain and cost dramatically less than welded or catalogue benches, because your team builds exactly what the task needs. Flexpipe Australia can design the first station with you; your crew can build the rest.