EN 1005: assessing ergonomics, postures, forces and movements in machinery

Why EN 1005 series is important for manufacturers

Ergonomics is often interpreted as a theme of comfort and this is not correct. In the context of machine safety, ergonomics involves reducing predictable risks to the operator: fatigue, biomechanical overload, repetitive movements, incongruous postures, excessive efforts, difficult access and human-machine interactions not adapted to the actual characteristics of users.

This is not the organisation of work: the user can organize shifts, training, procedures and rotations, but the manufacturer decides geometries, heights, weights, access, operating frequencies, required efforts and logic of interaction. If a machine is badly designed, the user can only compensate, and for ergonomics to compensate does not equal to design safely.

When CE marking, customer audit or technical review, a weak ergonomic assessment leaves open concrete questions: what manual tasks are expected? How many times are they executed? With what strength? From what position? With what accessibility? Do machine dimensions consider the anthropometric variability of operators? Can the components that need to be lifted actually be handled safely? Do cleaning and maintenance operations require worse postures than normal use? Reference

EN 1005 series helps to answer these questions with a technical approach; it is not enough to write in the instructions for use how to use the machine, it is necessary to demonstrate that the machine has been designed taking into account the predictable physical interaction between person, machine, equipment and manipulated components, reducing the risks related to ergonomics at an acceptable level.

Ergonomics in the Machinery Regulation: it is not comfort, it is safety

Regulation (EU) 2023/1230 maintains and strengthens the principle already present in the Machinery Directive: under the conditions of use envisaged, the operator's physical and mental stresses must be eliminated or minimized. The requirement concerns at least the variability of size, strength and stamina of operators, the need to avoid postures and demanding movements, the availability of space for body movements, the rhythm imposed by the machine and the adequacy of the human-machine interface.

Translated in design terms: ergonomics cannot be addressed only after the machine is complete by adding a note to the instructions for use. It has to enter into the layout, overall dimensions, access, working heights and component weights and in all stages of life of the machine.

This aspect will become even more relevant with the application of the Machinery Regulation from 20 January 2027, because the technical file will have to be increasingly robust and consistent; however, it is necessary to demonstrate a logical path: identification of tasks, assessment of physical risks, reduction measures, possible residual risks and consistent instructions.

What includes EN 1005 series

EN 1005 series, ’Safety of machinery – Human physical performance’, is divided into several parts. Each part deals with a specific aspect of human physical performance in the relationship with the machine. The correct approach is not to choose a single random part, but to map the real tasks of the operator and understand which parts of the series are relevant.

EN 1005-1: terms and definitions

The first part of the series is less operational, but still important; it helps us to draw up the technical file using consistent terms. If in the document we talk about handling, strength, posture, frequency, duration, recovery, task and operator, these concepts must be clear. The lack of definitions often leads to generic evaluations, difficult to defend.

In technical work this means describing the tasks in an observable way such as:

• Drawing reel from cart and insertion on tree
• lateral cover opening for change format
• extraction bathtub for cleaning
• upper carter removal for maintenance

Considering all phases of life of the machine that directly involve the operator.

EN 1005-2: manual handling of machines and components

EN 1005-2 is central when the operator needs to move parts of the machine or components connected to the machine. The typical case is the format change: guides, star wheels, feed screws, moulds, rollers, casings, hoppers, cutting units, tools, containers, coils, tools and gripping devices. In many sectors these elements are not huge, but are often moved, in narrow spaces and with unfavorable postures.

The assessment cannot be limited to nominal weight. It must consider grip, distance from the body, pick-up and placement heights, trunk twisting, component stability, required precision, frequency, duration, the working environment, available handling aids and foreseeable operator characteristics. A 10 kg component may be acceptable in one situation and problematic in another, for example when it must be positioned above shoulder height, away from the body, in an unstable or awkward position, or repeatedly at a high frequency.

The most effective design solutions are almost always mechanical and geometric: weight reduction of components, division into subgroups, adequate handles, dedicated trolleys, insert guides, lifting points, support devices, appropriate working heights, space for feet, elimination of obstacles and access that avoid unnecessary twists. The classic “two-person handling” can be a residual risk management measure, but should not become the standard response to a heavy or awkward design.

EN 1005-3: recommended limits of operational forces

Many machines require manual forces: open a guard, close a door, press a command, unlock a device, etc. EN 1005-3 standard is the reference to be considered when machine use requires operator force.

The force should not be evaluated only as a maximum value. They count direction, posture, duration, repetition, type of grip, friction, required accuracy, stability of support and population of users expected. A relatively low force can become critical if applied with the extended arm, the deviated wrist or the twisted trunk. A higher force can be tolerable if applied rarely, in a stable position and with a correct grip.

From the point of view of the manufacturer, the evaluation of the force for the operations is a concrete fact: it can be measured, it can be tested. In case of criticality, it can be easily corrected with:

• gas springs
• counterweights
• servoassistances
• better cinemas
• adequate handles
• reduction of friction
• Linear guides
• Optimisation of outlet points

from what describes EN 1005-3 standard, ergonomics becomes one of the areas where the difference between “ergonomic machine” and “non-ergonomic machine” emerges quickly.

EN 1005-4: postures and movements in relation to the machine

EN 1005-4 concerns the evaluation of the postures and movements taken by the operator during the interaction with the machine. It is a particularly important part in projects where the operator has to access internal areas, feed manually, control products, remove waste, clean, adjust, change format or intervene for recurring operations.

Critical postures are not only extreme ones, they can also be moderate postures maintained long or repeated often: neck bending to control a low display, lifted shoulders to reach a hopper, twisted trunk during loading, arm in extension to pick up pieces, deviated wrist to operate a command, kneeling to clean a lower area; risk increases when posture, strength and repetition are added.

In the technical file it is necessary to document the relevant postures with images, dimensions and description of the task; this must be done for the significant operations necessary during the phases of life in which the operator interacts directly with the machine (normal use, adjustment, cleaning, format change, ordinary maintenance, clearing jams and handling of removable parts).

EN 1005-5: high frequency repetitive movements

EN 1005-5 becomes relevant when the working cycle involves repeated high-frequency movements. The case is typical in semi-automatic machines: the operator feeds pieces, picks products, inserts components, performs controls, packs, orients objects, removes waste or performs repetitive gestures to support automation.

The risk depends not only on the individual action, depends on frequency, duration, recovery times, applied force, posture, precision, rhythm imposed by the machine and real possibility to interrupt or vary the task. A machine that imposes a rigid cadence can transform a simple gesture into a significant exposure. For this reason EN 1005 series must be read together with the ergonomic principle that the working rhythm should not be imposed by the machine when it produces discomfort, fatigue or physical stress.

The reduction measures can be different:

• automation of repetitive gesture
• power adapters, orientors, buffers
• intake systems
• correct support plans
• reduction of required force
• variation of the task
• reduction of cadence
• optimization of heights
• improvement of visibility
• shorter access

Here too the organisational measures taken by the user does not eliminate the design responsibility of the manufacturer when the risk arises from the configuration of the machine.

How to integrate EN 1005 into risk analysis EN ISO 12100

The correct way to use EN 1005 series is to use it when drafting the risk analysis in the project phase. The sequence is simple, but it must be done well.

1. Identify the machine life-cycle phases: transport, installation, start-up, normal use, adjustment, format change, cleaning, maintenance, troubleshooting, disassembly.

2. Locate the physical tasks performed by the operator at each stage: lift, push, pull, hold, press, rotate, reach, insert, remove, inspect.

3. Describe real conditions: mass of components, dimensions, distances, frequencies, duration, posture, direction of force, grip, available space, stability, visibility.

4. Combine the relevant parts of EN 1005 series and any complementary ergonomic standards.

5. Apply reduction measures according to the safety hierarchy: inherently safe design, technical measures, information for use only for residual risk.

6. Keeping evidence in the technical file: calculations, measurements, layout, photographs, test procedures, reviews, prototype checks and reasons for design choices.

This integration avoids one of the most common mistakes: to treat ergonomics as a separate appendix, disconnected from the hazards identified in the risk assessment.

• If a maintenance activity requires instructions for use extraction of a heavy group, the risk must appear in the risk analysis.
• If a guard requires a high force to be opened, the risk must appear.
• If the operator has to work folded to remove waste every twenty minutes, the risk must appear.

Evidence to be included in the technical file

A good ergonomic evaluation according to EN 1005 standard series must ensure that in case of audit, accident, dispute or customer request, the company must be able to demonstrate not only that it has mentioned the standard, but that it has been used in the design choices.

Concrete examples in packaging, food, pharmaceutical and automation sectors

Packaging:

EN 1005 series is particularly useful in areas where machines are automatic but human intervention remains frequent. In the packaging, for example, format changes can require movement of star wheels, guides, feed screws, cutting units, coils and casings; if these elements are heavy, difficult to grasp or placed on top, the machine generates ergonomic risk even if the automatic cycle is safe.

Food and Cosmetic

In the food and cosmetic sector, cleaning is often a critical phase. Tanks, hoppers, pipes, covers, conveyor belts and dosing units must be accessible without forcing the operator to twists, stretches or prolonged kneeling postures. A hygienically sound but ergonomically uncomfortable machine can create risks during washing, sanitizing and reassembly.

Pharmaceutical

In the pharmaceutical, the theme emerges on inspection, change format, maintenance in confined spaces and interaction with barriers, glove box or containment systems. Product safety must not compromise operator safety. The design must balance contamination, accessibility, required forces and posture.

Robotized lines

In industrial automation and robotic lines, the ergonomic risk often occurs in the residual activities: loading cassettes, retrieving pieces, gripper changes, cleaning grippers, work on conveyor belts, clearing jams. Automation reduces some risks, but can create others if the remaining manual operations are rare, difficult, heavy or performed in unfavorable positions.

EN 1005 and related rules: how not to confuse references

EN 1005 series does not live alone. In a serious machine project it connects to other references. EN ISO 12100 defines the general method of risk assessment and reduction, but there are other standards that can be important in the design and analysis of the machines:

EN 614 deals with ergonomic machine design principles. ISO 11228 standards concern manual handling, while ISO 11226 and ISO/TR 12295 can support the most general ergonomic evaluation.

The C-type standards, when they exist for a specific family of machines, can introduce more targeted requirements.

The designer must avoid two extremes. The first is to ignore EN 1005 because it is not required by the customer. The second is to use it mechanically, without connecting it to the real task. The standard must be used to demonstrate the technical reasonableness of the design, not to fill the list of applied standards.

It is also necessary to always check the current edition, the possible national transposition and the harmonisation status at the time of publication or marking. Technical standards change, harmonised lists may have limitations and a solid assessment must refer to the regulatory state actually applicable to the project.

Frequently Errors in Machine Projects

Operational checklist for technical office

Before closing the project, the manufacturer should answer at least these questions. If many answers are weak, the ergonomics evaluation is not complete.

1. Have all expected and reasonably foreseeable manual tasks been identified?

2. Are the masses of the removable components known and reported where necessary?

3. Was the withdrawal, deposit, loading, unloading, cleaning and maintenance fees verified?

4. Has the opening, closing, pushing, traction, rotation and tightening forces been considered?

5. Have critical postures been analysed on prototype, 3D layout or real machine?

6. Has repetitive movements been evaluated in relation to frequency, duration and machine rhythm?

7. Have design solutions been adopted before using organizational instructions or prescriptions?

8. Are the residual risks consistent with the instructions for use?

9. Does the technical file contain sufficient evidence to support the choices?

10. Has the status of the rules applied been verified at the time of the declaration of conformity?

How Waves Engineering supports manufacturers

Waves Engineering supports manufacturers in ergonomic machine evaluation by integrating EN 1005 into risk analysis and technical file. The aim is not to produce a theoretical document, but to identify the critical points of the project and to render them technically defensible: operator tasks, forces, postures, movements, accessibility, maintenance, cleaning and instructions.

Support can cover new machines, project revisions, existing machine audits, machine adjustments, document verification, compliance analysis for foreign customers and preparation of technical evidence to attach to the dossier. In the most critical cases, the most effective intervention is to anticipate the evaluation during 3D layout or design: to correct a dimension during design costs little; to correct it after installation can become a technical, economic and contractual problem.

FAQ

Is EN 1005 series mandatory for all machines?

No. Like all technical standards, it must be evaluated according to the hazards and tasks present in the machine. If the machine requires movements, manual forces, significant postures or repetitive movements, EN 1005 series becomes a very relevant reference to demonstrate compliance with ergonomic requirements.

EN 1005 replaces EN ISO 12100 risk assessment?

No. EN ISO 12100 remains the methodological reference to identify hazards, estimate and reduce risks. EN 1005 provides specific criteria for human physical performance and must be integrated into risk assessment, not used as a separate and disconnected document.

Is ergonomics about the manufacturer or just the machine user?

It's about both, but with different responsibilities. The manufacturer must design the machine taking into account the intended use and reasonably foreseeable behaviour. The user must arrange the work safely. If the risk arises from geometries, weights, access or forces decided by the manufacturer, it cannot be fully discharged on the organisation of the customer.

What should the technical file contain on the ergonomics evaluation?

It must contain evidence consistent with the present risks: description of the tasks, masses, dimensions, forces, frequencies, postures, reduction measures, tests, photographs or verifications, as well as the residual risks reported in the instructions for use. The level of detail must be proportional to the complexity and criticality of the machine.

Do automatic machines still have ergonomic risks?

Yes. Ergonomic risks are often concentrated in residual tasks such as loading, unloading, format changes, cleaning, maintenance, clearing jams, inspection and adjustment. Even a highly automated machine can present significant risks if the remaining manual tasks are strenuous, awkward or repetitive.

When should I evaluate EN 1005?

The best time is during design, before freezing the layout. At this stage it is still possible to change heights, access, masses, handles, support systems and mechanisms. Assessing finished machine ergonomics often means simply compensating for a problem already built.