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Principle 5
Reduce Excessive Motions
The number of motions required to do a task can have a profound
impact on both productivity and wear and tear of the body. Excessive
motions can create injury to sensitive tissue and joints, as well as
contribute to inefficient use of time. Whenever feasible, motions—
in particular, repetitive motions—should be reduced.
In many ways repetitive motions are time wasters, or at least a
red flag for such. This does not mean that all tasks involving repetitive
motions can be improved (altho many can); rather, these motions
often provide little or no value added to the product.
Many of these ideas used to reduce repetitive motions amount
to old-fashioned methods engineering, ideas that have perhaps been
neglected in a era of high technology. Striving for motion efficiency
is a concept that can be readily applied in many workplace
ergonomics activities.

Let the tool do the work—One of the best ways to

Let tools and machines do the work.
reduce repetitions is to allow machines and tools to do
the motions. Machines are good at performing repetitive
tasks endlessly, so they should be exploited. Good
examples are using a cordless screwdriver instead of a
manual one, a nail gun instead of a hammer, or an
electric drill versus a hand drill.
There is nothing particularly remarkable about this
concept; new applications for power tools are an
everyday occurrence. It is worth mentioning, however,
because there is often confusion about how to reduce
repetitive motions, and sometimes the obvious gets
overlooked.
There are countless ways to mechanize repetitive
manual motions, including:
• Parts ejectors to remove parts from machines.
• Magazines to feed parts into machines.
• Label dispensers to eliminate the need to pick up a
roll of labels and fumble to peel off one.
• Flipper devices.
• Fixtures of multiple tools.
• Total automation and robots.

Design for manufacture—Many of the basic concepts

of designing for manufacture are principles of
ergonomics. Ways to reduce motions include:
• Use snap-in parts, not ones that need fastening.
• Eliminate tangles and “sticky,” “springy” parts.
• Eliminate parts altogether.

© 2000 by Dan MacLeod

 Principles of Ergonomics 37

Design for motion efficiency—Another way to

reduce motions is to use the most efficient
workstation layout possible. Workstation changes
to improve heights, reaches, location, and
orientation of materials can eliminate many
unnecessary hand and arm motions.
For example, in a shipping department, when
a mail scale is placed on a level that puts the top of
the scale at the same height as the remainder of the
worksurface, the packages can be slid on and off,
rather than lifted. Similar designs can be used in
many assembly operations. Such small changes can
have an important impact when the volume and
Less work… …more
weight of materials are sufficiently high.
Good organization can eliminate some motions
altogether. Rather than moving items back and forth,
simply arranging them in the proper sequence can
eliminate wasted effort. As elementary as this
concept sounds, it is surprising how often it is
forgotten in everyday operations at work.

Reduce the range of the motion—There is a

distinction between a small, insignificant motion
and a large sweeping one. Thus, even if a motion
cannot be eliminated altogether, it might be
shortened. Instances where this rule of thumb may
apply include:

• Power tool triggers

• Keyboard keys

• Drill press arms

Slide rather than pick and place—It is almost

always better to slide items that must be handled
repetitively, rather than pick them up one at a time to
place in their locations. Although motions are still
required to slide items, the total number is usually
reduced. Techniques that enable sliding include:

• Move equipment closer together, equalize

heights, and tilt boxes and containers.

• Cut holes in workbenches to permit items or

scrap to drop directly into chutes, conveyors,
Sliding is better than picking up and placing or containers, thus eliminating the need to pick
each item. them up and place them repetitively.

© 2000 by Dan MacLeod

38
Rack and pinion—one motion yields multiple turns.
Box stands can be hinged so that the boxes can
slide away automatically, eliminating the need to
repetitively pick them up and carry.
© 2000 by Dan MacLeod
Motion-saving mechanisms—Similarly, there are
numerous mechanical devices that can be brought
into play in the effort to reduce repetitive motions:
• Gearing—one turn yields multiple turns.
• Rack and pinion mechanism—one motion
yields multiple turns.
• Old-fashion sewing machine pedal—one stroke
yields multiple reciprocal motions.
• Yankee screwdriver mechanism—one push
yields multiple turns.
• Ratchet—eliminates the motions of releasing
hold of a handle only to grasp it again.
Hoppers—Instead of using manual scoops to
handle powdered materials, hoppers reduce motions
and save time. Similarly, bulk handling systems and
pumps can save motions in the handling of both
powders and liquids.
Packaging stands that tip—Stands used to hold
boxes for packaging of products can be fitted with
hinges to allow the supporting surface to drop to
an angle that permits the boxes to slide to a takeaway
conveyor. Tilters of this type serve to eliminate the
motions that are otherwise required for the box to
be picked up, carried, and placed elsewhere.
If necessary, rollers can be added to the
supporting surface to facilitate the sliding.
Furthermore, cylinders can be added to these tilters
to activate them with a push of a button. This
technique can be used both for stands that are
horizontal as well as stands that have already been
angled to reduce reaches.
Keep materials oriented—Feeding parts and
materials in the correct orientation to a workstation
can reduce motions. In particular, a frequent and
senseless source of repetitive motions is the need
to reorient materials that were once oriented. Ideally,
parts should never be allowed to become jumbled
because it then takes extra work and more motions
to straighten them out again. Typically, careful
design of chutes and conveyors can keep the
materials in their orientation.
 Principles of Ergonomics
Feeding rolls of paper into the sheeter in a reversed
orientation saved multiple flipping motions.
Low-cost “automatic” parts dropper,
© 2000 by Dan MacLeod
39
Similar examples can be found in how parts
are placed on conveyors or on carts to be transferred
to the next operation. With some thought, wasted
motions can often be eliminated.
Pneumatic tubes used to feed screws to a screw
gun provide another example. These feeders keep
parts in the same orientation, and they also eliminate
altogether the need to pick up and place the screws
manually, thus saving many motions.
Automated operations provide helpful insights
on methods to keep parts oriented. Because the
machines cannot reach into a box of jumbled parts,
select one, and place it in the correct position,
techniques have been developed to keep parts
oriented perfectly. The most common example is
the vibrator bowl. These same techniques can also
be used to eliminate motions in manual work.
A case example of orienting materials properly
to save motions comes from a paper manufacturing
operation. An ergonomics evaluation revealed that
the first step of a number of operations was to
repetitively flip heavy reams of paper merely to put
the right side up. Then the ergonomics team
discovered that if rolls of paper were fed into the
sheeters (the machines that cut the rolls into flat
stacks of paper) with the paper coming off the top
rather than the bottom, it eliminated the need to flip
them afterward—a cost-free improvement.
Mount tools—The classic example of mounting a
tool to eliminate unnecessary motions is the bar
code scanner. Rather than picking up and then
putting down for each use, the scanner can be
mounted and the objects with the bar codes slid
under. The standard practice of hanging tools from
counterbalances also demonstrates good use of this
rule. Depending upon the situation, mounting can
save time and eliminate a sizable number of motions.
Overhead hook conveyors—A widespread source
of repetitive motions is hanging and unhanging
parts onto overhead hook conveyors, such as for
transporting parts thru paint or wash areas. Much
of this is difficult, if not impossible, to resolve, with
the exception of certain types of parts that can be
dropped: It is possible to automate the release of
parts by using scissors hooks or other types of
releasing hooks. One type of “automatic” system
40

amounts to having a simple bar at the dropping

station that lifts up each hook as it comes by.

Keyboards—The archetypal instance of repetitive

motions in our society is working with the computer
keyboard. Design techniques that have reduced
motions include:

• Icons, menus, keyboard shortcuts, and mouse

devices that have reduced the amount of hand-
typed codes that were needed in the past.

• Shortened strokes of keys (especially in contrast

to manual typewriters).

Improved technology reduces keystrokes. • New input devices like touchpads even further
reduce the motions needed.

• Voice activation software can reduce the

amount of keying, and in certain circumstances
can eliminate all or nearly all motions.

Improve work technique—It is not uncommon

Video can provide a powerful training tool.
to see two employees working side by side on the
same task, with one employee working smoothly
and the other with hectic, exaggerated, and wasted
motions. It is important to help employees learn to
use the most efficient, least injurious methods. This
may involve breaking old habits, but could also be
caused by simply not knowing better ways.
Videotaping different employees to show both
the good and bad methods can sometimes be helpful.
Obviously, this must be done with respect and
concern for the people involved to avoid any
unintended embarrassment or the appearance of
being a reprimand. Under the right circumstances,
videotapes can be a powerful tool.

Be Creative
One of the barriers to progress is that people have preconceptions
about how various tools, tasks, and pieces of equipment ought to
look. Fortunately, ergonomics programs in industry can help break
these barriers by challenging conventional thinking. With some
creativity, hundreds of ways can be found to reduce unnecessary
motions, thus improving human well being as well as increasing
productivity.

© 2000 by Dan MacLeod