Background Total Hip Arthroplasty (THA) surgery is physically and cognitively challenging. Sub-optimal posture during component impaction may influence surgeon’s ergonomics and fatigue. Methods Thirty THA procedures were executed for 3 days. Only during the first day, manual impaction (MI) was performed. Postural risk was evaluated with Rapid Upper Limb Assessment (RULA) and Rapid Entire Body Assessment (REBA) score. Three cognitive tasks (Simon, pattern comparison and pursuit rotor test) and five physical tests (isometric wall-sit, plank-to-fatigue, handgrip, supra-postural task, and shoulder endurance) assessed surgeon’s psycho-physiological load in the morning, midday, and afternoon. Surgeon’s cortisol concentration and sound level of the broaching process was also recorded. Results RULA and REBA scores were 1.7 to 3 times lower with automated impaction (AI). Physical exhaustion was lower with AI: isometric wall-sit test (10.6% vs. 22.9%), plank-to-fatigue (2.2% vs. 43.8%), supra-postural task (-0.7% vs. -7.7%), handgrip force production (dominant hand -6.7% vs. -12.7%; contralateral +4.7% vs. +7.7%), and in shoulder endurance (-15s vs. -56s). After AI, the cognitive performance showed faster response times and lower error rates for all cognitive tests compared to MI. The salivary cortisol level decreased during the AI-days by 51% in comparison to a 38% increase following the MI-day. Mean broaching time with AI was 7’3’’ compared to 6’20’’ with MI. The mean sound level with the AI-device was 64.3 dBA compared to 68.2 dBA with manual impaction. Conclusions Automated THA component impaction improved the surgeon’s ergonomics which resulted in reduced hormonal stress levels and lower physical and cognitive exhaustion.