Minimising Motion Waste – Streamline Your Workspace for Efficiency

Often overlooked, motion waste not only slows down operations but also takes a toll on workers, leading to fatigue, frustration, and even errors. Find out more in our 8 Wastes blog series.

In production and manufacturing, small inefficiencies can have a big impact, and motion waste is a prime example. It’s the unnecessary physical effort workers expend — like stretching, bending, or walking — when tasks aren’t set up for optimal flow.

These inefficiencies not only slow down operations but also increase physical strain on employees, leading to fatigue and errors. In this blog, we’ll break down what motion waste is, why it matters, and how you can create a more efficient workspace using practical tools and solutions.

What Is Motion Waste?

Motion waste refers to any unnecessary physical movement performed by workers while completing their tasks. This waste often results from disorganised workstations, misplaced tools, or layouts that don’t prioritise efficiency.

For example, imagine a technician assembling small electronic components. The tools and parts they need are stored on a shelf above the workstation, requiring them to repeatedly stand and stretch to retrieve items. Over the course of a day, these small motions add up, increasing fatigue and slowing down the assembly process. A properly configured workstation with integrated tool storage and adjustable shelving would eliminate these unnecessary movements, saving time and reducing strain.

It's worth noting that Motion Waste is often confused with Transportation Waste - which you can learn more about here!

Why Motion Waste Matters

Motion waste doesn’t just inconvenience workers — it creates a ripple effect that impacts productivity, morale, and operational efficiency. By addressing unnecessary movements, you can unlock significant improvements in workflow and output. Here’s how motion waste takes its toll:

Increased Fatigue: Every unnecessary reach, bend, or step adds up over the course of a shift. Over time, this repeated strain causes physical fatigue, reducing worker focus and slowing down task completion. For example, an assembly worker repeatedly stretching to grab a tool from a high shelf will tire more quickly, leading to slower production and potential ergonomic injuries.
Longer Production Times: When workers have to spend extra seconds retrieving tools or materials, these delays compound across multiple tasks and workers. This results in extended production cycles and reduced throughput. Imagine a technician who has to frequently leave their workstation to retrieve parts stored across the room—these lost moments ultimately translate to hours of wasted time.
Higher Risk of Errors: Fatigue and frustration from inefficient setups can lead to mistakes. Disorganised workspaces force workers to multi-task unnecessarily, dividing their attention between finding what they need and performing their actual tasks. For instance, a cluttered bench with misplaced tools increases the chance of selecting the wrong tool or using a suboptimal one for the job.

Addressing motion waste is about more than saving seconds—it’s about building a workspace that prioritises employee well-being and operational efficiency.

How to Identify Motion Waste

Spotting motion waste requires a keen eye on the physical actions workers perform while completing tasks. Motion waste often creeps into workflows unnoticed, but its cumulative effects on productivity and employee well-being can be significant.

To identify motion waste, focus on repetitive or unnecessary physical movements that don’t directly contribute to task completion.

Key Signs of Motion Waste:

Frequent Reaching: Workers often extend their arms to grab tools or materials stored too far away. For instance, if commonly used items are placed on the far end of a workbench or high on a shelf, employees must strain to reach them, slowing down the task at hand.
Bending and Stooping: Regularly bending down to access items stored below the workstation can cause discomfort and fatigue. Over time, this repetitive motion leads to slower workflows and potential ergonomic issues, such as back pain or strain injuries.
Unnecessary Trips Around the Workstation: Workers often walk around their station to gather tools or components that could be kept within arm’s reach. For example, if assembly tools are stored in a separate drawer or another workstation, retrieving them creates delays and interrupts workflow focus.
Searching for Misplaced Tools or Parts: A disorganised workstation forces employees to spend time and energy looking for the correct tools or materials. This not only wastes time but also shifts their focus away from productive work.
Awkward Movements: Tasks that require twisting, leaning, or prolonged standing in uncomfortable positions signal a lack of ergonomic setup. For instance, a poorly positioned monitor or tool rail might cause workers to overextend themselves repeatedly throughout the day.

Practical Steps to Identify Motion Waste:

Observation and Mapping: Watch employees as they perform their tasks and map out their movements. Create a "motion diagram" to visualise unnecessary steps or repetitive actions. This is especially useful for high-frequency tasks, such as assembly or quality control.
Feedback from Workers: Involve employees in identifying inefficiencies. Workers are often the best source of insight into what slows them down or causes physical strain during their routines.
Audit of Workstation Layout: Assess the current organization of tools, materials, and equipment. Are frequently used items within easy reach? Is there a logical flow to the arrangement? These questions can uncover hidden inefficiencies.
Review Ergonomics: Check if workstations are adjusted to fit individual workers. Improper desk height, poorly positioned monitors, or inadequate seating can all contribute to unnecessary motion.

Solutions to Reduce Motion Waste

At Gigant, we understand the importance of motion efficiency in production environments. Our products are designed to eliminate wasted effort and keep workflows smooth. Here are 3 top tips to reduce your motion waste:

1. Customisable Workbenches

A well-designed workbench is the cornerstone of an efficient workspace, and can be your key weapon in eliminating unnecessary movement.

Gigant’s customisable workbenches offer:

Integrated Storage Options: Choose from modular drawer units, shelving systems, or tool panels complete with hooks and brackets for storing tools. You can even suspend frequently used tools from overhead rails using suspension trolleys. Getting the perfect, bespoke setup ensures that tools, components, and materials are always close at hand.
Height Adjustability: All of our workbenches are mechanically height adjustable, but for maximum flexibility our motorised benches allow workers to set the perfect ergonomic position for their tasks.
Stability and Durability: Designed to handle heavy-duty use, these workbenches remain secure and stable, even during precision tasks like assembly or repairs.

2. Tool and Material Storage Systems

Effective storage solutions are essential for reducing time spent searching for tools or materials. Gigant offers:

Wall-Mounted Tool Racks: These racks keep frequently used tools visible and easily accessible. Perfect for reducing trips across the workshop.
Drawer Units with Inserts: Our range of drawer inserts ensure every tool has a designated spot. Missing items are immediately noticeable, saving valuable time during busy shifts. We can also support with custom foam in-fills for drawers for specialised solutions.
Part Bins and Cupboards: Purpose-built for small components, these systems are ideal for keeping screws, bolts, and other essentials organised and within easy reach.

3. Mobile Workstations and Trolleys

For dynamic workflows, mobile solutions allow you to bring tools and materials directly to where they’re needed. Options include:

Mobile Workbenches: Compact and manoeuvrable, these workstations transport your tools and work station to where you need to work
Height-Adjustable Mobile Benches: These benches combine the benefits of height adjustability with castors, making them perfect for flexible layouts.
Shelf Trolleys: These lightweight trolleys can be customised with trays, bins, or locking compartments to transport delicate or heavy items between stations.

Example scenario of reducing motion waste

To bring it all to life, check out the below example scenario before and after optimising a working setup to reduce motion waste:


Before Optimisation	After Optimisation
At a small electronics assembly plant, workers repeatedly bend down to retrieve components stored in bins under their workstations. Screwdrivers and other tools are kept on a shared rack across the room, requiring them to leave their station multiple times per hour. These repetitive movements not only waste time but also contribute to worker fatigue and errors.	Using a customised workbench setup, bins are placed on an adjustable shelf just above the work surface, within easy arm’s reach. Tools are mounted on a tool panel at the back of each workbench, ensuring they’re always accessible without leaving the station. These simple adjustments eliminate unnecessary movements, improving both productivity and worker comfort.

Key Takeaways

Motion waste may seem minor, but its cumulative impact can significantly slow down your operations. By organising tools, customising workstations, and investing in mobile solutions, you can create a workspace that keeps employees focused and productive.

Ready to streamline your workspace? Explore Gigant’s motion-saving solutions or get in touch today!