Assembly Workstations
Purpose-built lean production benches, packaging tables, and inspection stations built from modular aluminum T-slot framing. Every configuration is engineered around your process — work surface height, storage layout, overhead organization, utility routing, and footprint — so operators have exactly what they need and nothing they don't.
Key Features
Engineered around the specific requirements of your process, operator, and facility.
Lean-Cell Compatible Sizing
Standard and custom footprints sized for lean cell layouts, U-shaped lines, and straight-line assembly flows — with consistent frame heights that integrate directly with flow rack and conveyor systems.
Integrated Tool & Parts Storage
Under-bench drawers, pegboard and perforated panel uprights, bin rails, and overhead shelving built into the frame — so tools and components are at the point of use, not spread across the floor.
Multi-Operator Configurations
Side-by-side and back-to-back station configurations with shared uprights reduce material and floor space while maintaining independent work zones for each operator.
Work Surface Options
Laminate, hardboard, stainless steel, ESD mat, and aluminum plate surfaces — each selected for the specific assembly process, cleanability requirement, or electrostatic sensitivity.
Power & Lighting Integration
Under-shelf LED lighting, outlet strips, USB charging, and cable management channels are integrated at the design stage — not added as afterthoughts with clamps and zip ties.
Rapid Reconfiguration
Aluminum T-slot framing allows accessories to be repositioned, surfaces to be swapped, and stations to be extended without drilling, welding, or purchasing new frames.
Applications
Common applications across manufacturing, laboratory, and professional environments.
- Lean Production Assembly — Stations designed for one-piece flow, kitted assembly, and takt-time-balanced work cells with bin lanes, tool shadow boards, and visual management provisions.
- Packaging & Kitting Benches — Wide-format stations with label printer mounts, tape dispenser rails, scale platforms, and ergonomic standing or seated configurations for repetitive packaging operations.
- Inspection Benches — Dedicated inspection surfaces with overhead lighting, part fixture provisions, documentation holders, and reject/accept bin positions for inline and end-of-line quality stations.
- Sub-Assembly & Prep Stations — Pre-work and staging stations positioned upstream of main assembly lines — sized for sub-assembly fixtures, torque tools, and work-in-progress storage.
- Line-Side Replenishment Stations — Point-of-use stations with integrated flow lane inbounds, empty return routes, and supplier labeling provisions for JIT delivery directly to the operator.
- Multi-Shift Production Stations — Stations designed for consistent shift changeover — with standardized tool locations, consumable storage, and cleaning provision so every shift starts in the same condition.
Specifications & Capabilities
Standard specifications — all dimensions and configurations are available custom.
- Frame Profile: 45 mm or 90 mm T-slot aluminum extrusion; mixed frame sizes available within a single station.
- Work Surface Height: Standard 34", 36", and 40"; custom heights available; adjustable-height frames available.
- Work Surface Depth: 24", 30", 36"; custom depths available.
- Work Surface Width: 36" to 96" standard; longer spans available with intermediate uprights.
- Surfaces: 3/4" hardboard, phenolic laminate, stainless steel, ESD mat, aluminum plate.
- Storage Options: Under-bench drawers, shelves, bin rails, pegboard uprights, overhead shelving.
- Lead Time: 3–5 weeks from approved drawings.
Frequently Asked Questions
What frame profiles are used for assembly workstations?
Assembly workstations are built from 45mm or 90mm T-slot aluminum extrusion, selected based on the span length, load per tier, and accessory weight. The 45mm profile is standard for most assembly stations with spans up to 1500mm and moderate accessory loads. The 90mm profile is used for wider spans, heavy overhead shelving, or stations that must resist lateral forces from torque tool reaction. Mixed-profile frames, with 90mm uprights and 45mm crossmembers, are common for tall multi-tier configurations.
What standard work surface heights are available?
Standard work surface heights are 34 inches (seated), 36 inches (standing average), and 40 inches (tall standing or sit-stand). Custom heights are available at no additional cost since the T-slot frame is cut to order. For multi-shift operations with operators of varying heights, Modular Solutions recommends an adjustable-height frame option with a preset range rather than a fixed height.
How are tools and components organized on an assembly workstation?
Tool and component storage is built into the frame using pegboard or perforated panel uprights for shadow-boarded hand tools, bin rails for parts bins at the back of the work surface, under-bench drawer units for consumables and documents, and overhead shelving for larger items. All storage elements attach directly to the T-slot frame uprights, keeping the work surface clear and placing everything at the point of use. Label holders and color-coded bin dividers can be specified for 5S compliance.
Can assembly workstations be connected to conveyor or flow rack systems?
Yes. Modular Solutions assembly workstations are designed with consistent frame heights that align directly with standard flow rack and conveyor interfaces. Gravity roller infeeds, part transfer bridges, and line-side bin lane supports are integrated into the workstation frame at the design stage. The T-slot frame accepts conveyor side rail brackets without drilling, allowing the station to be physically docked to adjacent conveyor sections.
What is the lead time for a custom assembly workstation?
Custom assembly workstations are typically shipped in 3 to 5 weeks from approved drawings. This includes design review, extrusion cutting, hardware assembly, work surface fabrication, and quality check. For standard configurations with no special surfaces or accessories, lead time is often 2 to 3 weeks. Repeat orders of a previously documented workstation can be turned in 1 to 2 weeks.
Start Your Workstation Project
Send us your process requirements, sketch, or CAD layout — and we'll return a quote with layout options.
Email Us for a Quote Contact FormModular Solutions — 4280 Giddings Rd, Auburn Hills, MI 48326 | 248-625-1864