Industry Case Studies

Here are some elceted case studies form the Electronics Manufacturing industries.


Need: Bloomberg assembles the computer and loads software based on the customer’s information needs. Their recent explosion in growth required workstations in all departments- shipping, receiving, assembly and test.

Solution: C-Leg Series workstations and accessories to accommodate tools and supplies needed for the entire production process. Assembly departments needed sufficient lighting, shelving, air distribution and bin storage. The test department requested a custom support arm to accommodate the bank of computer monitors and cable troughs to keep cords under control. Shipping and receiving took advantage of high weight capacities and heavy-duty construction for the large volumes of parts and computers cycling in and out of the facility.


Need: Workstations for manufacturing & assembly of point of sale printers.

Solution: Production Basics modular workbenches and a new assembly line configuration saved the customer 1-2 feet per station. This station configuration improved efficiency as there are many product variations and manufacturing has to adapt to these variations. Workstations were combined with conveyors for easier assembly and product handling.


Need: A circuit board assembly, inspection and box build workstation.

Solution: Flextronics chose Production Basics to provide 200 workstations after evaluating a prototype unit. Flextronics’ ‘Flex Bench’ is 36 inches wide, with a 64-inch high Upright Open Frame, adjustable worksurface height and cantilevered leg design. To make it easy for any person to position the assembly bench, heavy-duty, 5-inch locking casters were installed on all units. Overhead and under-shelf fluorescent lights illuminate the working area. A platform footrest with an adjustable angle is an ergonomic workbench feature that assembly operators appreciate. Stations are outfitted with the appropriate accessories— items such as laminate shelving, bin rails, CPU holders and swing-arm monitor trays—to help organize materials and equipment. Workstations include integrated power strips, making it easy to plug in and power-up. With the Flex Bench, Flextronics can configure their build areas in the most efficient way and quickly respond to changes in production flow. Although it was originally intended for test equipment, the Flex Bench plays many assembly roles including part of a box-build configuration or linear assembly. Flextronics is able to immediately increase their productivity and continue to provide quality, on-time product to their customers. Flextronics can now effectively manage production fluctuations while maintaining seamless customer service


Need: Workstations for assembly, inspection and testing of computer systems.

Solution: The customer evaluated seven other workstation manufacturers before choosing a custom workstation from Production Basics. The work benches were eight feet long, split into five-foot and 3-foot wide section. These sections allowed operators to separate tasks and reduce reaching, improving workstation ergonomics.


Need: Workstations that accommodate various equipment modules for testing wireless and radio frequency products.

Solution: An eight-foot surface on a six-foot frame allows for one foot of overhang on each side for easy access and movement under the worksurface. A sloped shelf makes it easier for operators to monitor instruments.


Need: An electronic work bench suitable for inspection and testing.

Solution: Back-to-back and Side-by-Side C-Leg workstations with ergonomic Comfort Edge worksurfaces, were installed in their facility.


Need: Reconfiguration of 200 workstations

Solution: Production Basics, systems integrator Rapistan (now Dematic) and Compaq worked together to complete this automated storage and retrieval project (ASR). Compaq reconfigured computers in this high tech facility for large Fortune 500 companies requiring machines with the same softeare and hardware. Computers traveled on a custom tray to a custom workstation by an ASR system. The operator slid the tray toward their work bench by activating a pneumatic ball transfer system. Operators were able to configure four computers per workstation, then activated the ball transfer system again to send computers back to the storage area.


Need: Reconfiguration of 80 workstations

Solution: Eight-foot wide work tables with a custom stainless steel worksurface for use in a computer reconfiguration area. Tech Data also utilizes the heavy- duty B-Leg, to increase the weight capacity of the industrial workstation.


Need: This workstation project started in one department so the operators could evaluate the work benches and ensure satisfaction with the product.

Solution: Soon after the installation, other departments also wanted to upgrade their stations that improved organization and facility aesthetics.


Need: JDS Uniphase needed a fiber optic design & manufacturing workstation that was ergonomically sound, fit their equipment and was available for a test drive.

Solution: Production Basics initially provided a workstation for a 21-day evaluation. The demo work bench was chosen over the original 1st choice station because of the features and service the customer experienced. Electronic work benches were integrated with a 3M constant ESD monitor, 4-inch casters for mobility and a height adjustable B-Leg for weight capacity and ergonomics.


Need: When it was time Broadtech to move into a new facility, they looked into buying used assembly benches.

Solution: After researching products that were available, Broadtech determined that new workstations were worth the investment. They would be able to get the style and color they wanted by choosing from a broad product line like Production Basics, along with support, 10-year warranty and ability to expand their work bench configuration with additional products and accessories. Broadtech installed a conveyor to work in concert with their workstations, helping to facilitate product movement. The product is conveyed to the next operator, reducing handling and improving efficiency.


Need: Work benches for cellular phone repair.

Solution: Work benches were installed making the best use of space in a small area. Corner workstations and pedestal drawers provided adequate workspace for repairs and completion of paperwork.


Need: A custom server cart designed to make testing computer hardware easy and organized for the customer.

Solution: The 19-inch wide by 70 inch high by 35 inch deep framed cart included twelve pairs of support brackets (2.5 inch by 2.5 inch by 32 inch) that could be easily adjusted to accommodate different sized equipment. A full shelf accommodates a test monitor and keyboard for operator convenience. The cart included several surge protected power strips for convenient powering-up and cable troughs for cord management. To protect against static shocks, the cart is finished with a durable ESD epoxy powder coat and includes a drag chain. Four-inch locking casters ensure stability and safe product handling throughout Whalley's facility.


Need: 40 cantilevered work tables with upright system.

Solution: At the workstation, Widex operators manufacture hearing aids. This includes inspecting products and performing finishing tasks to ready hearing aids for distribution. Widex created a linear configuration using a custom cantilevered leg work table and standard accessories. Each workstation was outfitted with a Power Rail, Bin Rail, Laminate Shelf and drawer.


Need: Workstations for cell phone repair and remanufacturing

Solution: Operators using the ESD workstation are involved in all aspects of the remanufacturing process including cosmetic repair, component replacement, software upgrades and testing. This customer also uses Production Basics work benches for kit assembly and packaging. To increase ergonomics in the facility, this customer chose a bullnose edge for the worksurfaces.