Multifunctional, ergonomic workstations for assembly and repair at KLM Maintenance & Engineering

Together with Human Workspace KLM realized a series multifunctional, ESD-safe and electrically height-adjustable workstations that bring multiple processes together on a single workstation. The result is a future-proof work environment with increased capacity, more efficient workflows, and a higher degree of ergonomics and safety.

Challenge: realizing more capacity within the same available space

In the Hydraulic Components department, hydraulic parts are tested, cleaned, repaired, documented, and recertified. The increasing volume of work necessitated an expansion of capacity, while the available floor space remained the same. It was decided to further optimize the workspaces. Within KLM Engineering & Maintenance, Ruud Verzijlberg, Project Manager Component Tech Center, Benjamin Lopez Diaz, Equipment Maintenance Engineer and Nanne van Schravendijk, Equipment Specialist took the initiative and started to critically analyze the existing processes.

Based on their daily practical experience, they mapped out the key challenges:

• Create more capacity without additional floor space.
• Combining multiple tasks at one workstation.
• Improving ergonomics for employees.
• Smooth transfer of tasks between work teams.
• Working safely with hydraulic fluids such as Skydrol.
• Organizing the workplace more clearly and efficiently.

In their search for new workplaces, they came via a recommendation from a sister organization. EPCOR in contact with Human Workspace.

Collaboration as the basis for a future-proof solution

From the initial assessment, the specialists from KLM Engineering & Maintenance and Human Workspace collaborated intensively. The focus was not only on technical requirements, but primarily on the daily practices of the employees. Throughout the project, Ruud, Benjamin, and Nanne served as substantive sparring partners. By combining their practical knowledge with the expertise of Human Workspace, workplace solutions were created that fully align with the department's processes and provide room for future growth.

One multifunctional workspace for multiple processes

Where previously multiple workstations and tools were required, virtually all work now takes place at a single multifunctional workstation. Each workstation supports, among other things:

• Administrative tasks;
• Inspection and repair of hydraulic components;
• Drainage of hydraulic systems;
• Storage of tools, parts, and IT equipment.

Because all materials have a fixed place, employees always have the right tools within reach. This reduces searching and walking around and contributes to an organized workplace in accordance with Lean principles. An employee explains:”You can set up the workspace exactly as you like. Everything has a fixed place, so you never have to search and can work faster.\\\”

Moreover, by reducing the work tables from four to three meters, extra space was created for further expansion of the department.

Ergonomics supports productivity

Because multiple employees in different shifts use the same workstations, ergonomics played an important role during the design. Ruud Verzijlberg explains:

”The goal is for one work crew to be able to take over the work of the other without too many problems. In doing so, the ergonomics and comfort of the employees must remain guaranteed.”

The electrically height-adjustable work tables make it easy to switch between sitting and standing work. Thanks to personal memory settings, every workstation is instantly at the correct working height at the touch of a button. Furthermore, the robust steel construction, powerful actuators, and integrated collision protection ensure safe and reliable operation, even with intensive daily use.

The work tables also offer advantages when processing heavy components. Components up to 200 kilograms can be safely slid from a transport trolley onto the work table. This significantly reduces lifting, reaching, and physical strain.

Working safely with hydraulic fluids

An important part of the solution is the integrated drip tray in the work table. Hydraulic components regularly contain Skydrol, a hydraulic fluid that must be safely collected during maintenance work. Therefore, the workstations are equipped with:

• An integrated drip tray;
• A grate on which components can drain in a controlled manner;
• A cover plate that makes the workplace fully usable again immediately;
• A worktop that is resistant to Skydrol and easy to clean.

As a result, a separate drainage cart is no longer necessary, and multiple activities can safely take place at the same workstation. According to Ruud Verzijlberg, this yields immediate benefits:”Because the drip tray is integrated into the workstation, we can drain the units directly on the work table. That works much more efficiently.\\\”

Results

For Ruud, Benjamin, and Nanne, one goal was central: to develop a workplace that truly supports daily practice. Their technical knowledge, practical experience, and commitment formed the basis for the final design. By actively involving users from the start and continuously testing against real-world conditions, a solution emerged that is not only technically sound but also adds daily value for employees.

Thanks to the new workspaces, KLM Engineering & Maintenance has a flexible working environment ready for further growth. Ruud Verzijlberg looks back:”When you start a project, everything is still theoretical. Then you see the design in 3D, and ultimately, it is wonderful to experience that everything we conceived together actually works in practice..\\\”

Ergonomic, future-proof workspaces from Human Workspace

Human Workspace designs, advises on, and realizes ergonomic industrial workspaces for production, maintenance, MRO, logistics, assembly, high-tech, and laboratories. By combining processes, ergonomics, and technology, workspaces are created that contribute to higher productivity, safe working practices, and sustainable employability. Thanks to modular Treston systems Workplaces easily grow along with changing processes, and organizations remain ready for the future.

Project Services: from engineering to continuous improvement

Human Workspace oversees the entire process: from engineering, 3D design, and prototyping to the production, installation, and maintenance of ergonomic workstations and modular packing tables. A dedicated project manager ensures that all disciplines collaborate seamlessly and that the workstations align perfectly with the logistical processes. We remain involved even after delivery and optimize workstations based on practical experience. Thanks to short lines of communication and our own technicians, improvements can be implemented quickly.