I was recently brought out to give ergonomic advice on a complex workstation: a control room with 14 screens, used by operators across long shifts.
The organisation was being proactive. No major injury had been reported, but they recognised that the operators were spending their days in suboptimal positions. That's the cheapest time to fix something, before it becomes time off and a claim.
How the control room assessment worked
I interviewed the operators and looked at how each of the 14 screens was actually used. Eight were on a shared wall display and six were on the desk. Getting a clear picture of what the operators used each screen for was key to my recommendations on positioning.
What I found
I noted several things that were contributing to suboptimal ergonomics:
- The workstation suited the room, not the people using it. Operators were regularly forced into awkward head and neck positions to look at screens and perform their required duties. All eight wall screens meant tilting the head back to view them.
- Clutter pushed screens too far away. Multiple keyboards, documents and equipment crowded the desk, so the screens sat further from the operators than is ideal. People were reaching and straining to see the screens and use the keyboards, phone and mice.
- The chair didn't fit everyone. It was losing padding and the seat depth couldn't be adjusted, so on shorter operators the front edge pressed into the backs of their knees. When it was set at the right height for the desk, their feet no longer reached the floor. These postures could result in leg, neck and back discomfort after prolonged periods.
- Long shifts, with breaks at the desk. Shifts ran 10.5 hours with no scheduled breaks, so breaks were taken at the workstation. A break at the desk keeps the same posture, the same screens and the same alarms, so it isn't real recovery.
- Frequent alarms added to the load. The operators said many alarms were unnecessary, and all agreed. Extra alarms add mental load, make sustained attention harder and make it easier to miss the ones that matter.
Control room workstation design: what I recommended
My recommendations covered both the set-up and the people.
For the set-up
- Reduce desk clutter. Swap large keyboards that aren't used often for keypads, or tuck them away on under-desk slides. This allows the frequently used screens to sit at a comfortable distance.
- Position screens based on task and frequency of use. The screens operators rely on most should sit where they are easiest to see, with occasional-use screens placed further out. Screen position should follow the work and how it is performed, not the space available.
- Consider moving the workstation. Moving it back from the wall screens reduces how far the neck has to tilt back to see them. However, if the workstation is moved too far back, the screen contents become hard to see, so display size may need a look too. Adjustable mounts on the wall screens let different operators set them to suit themselves.
- Provide a new adjustable desk. Choose one that suits the tasks and the number of screens, with room for the equipment that is needed and a way for each operator to set the height to suit them, in both sitting and standing. A sit-to-stand desk can also encourage regular movement and postural changes throughout the day.
- Choose a chair that adjusts for all heights and sizes. This means a proper 24-hour operator chair, including seat pan depth adjustment.
- Provide a footrest in the meantime. At the right chair height for the desk, operators' feet didn't reach the floor. An adjustable footrest lets them sit with their feet supported, which supports a more comfortable posture. This is an option while awaiting the new height-adjustable desk.
- Review the alarms. Make sure unnecessary mental load and distractions are avoided.
For the people
I recommended regular movement and postural changes through the shift. Even a well set-up workstation can't remove the risk of discomfort that comes from staying in one position for hours.
Most of the fixes are about changing the workstation to fit the operators who use it, rather than asking people to adapt to it. For the business, that means fewer claims, better retention and fewer fatigue-related errors in a safety-critical environment.
Key takeaways
- Don't wait for the injury report. Prolonged awkward positions and minor discomforts are signals that a workstation may need an assessment.
- Consult with the operators. They know the tasks and how they are performed, and what bothers them most about their set-up. Their input is essential for effective implementation.
- Good ergonomics isn't set and forget. A workstation should be easily adjustable for everyone who uses it. When you design a set-up for the "average" person, you design it for no one.
Is it time to look at your control room?
A few questions worth asking:
- Do operators regularly tilt or turn their heads to see screens?
- Is the desk crowded, with screens pushed back from where people sit?
- Does the chair adjust for different body sizes?
- Do operators get real breaks away from the desk?
- Do operators say some alarms aren't needed?
If the answer to any of these is yes, it's worth a closer look before it becomes an injury.
Book a control room ergonomic assessment
TaskFit provides ergonomic assessments and job task analysis for control rooms and other complex workstations in Cairns and across Far North Queensland. We look at the worker, the task and the work environment together, rather than only treating the individual. If you'd like to talk about a workstation in your organisation, get in touch to book an ergonomic assessment.