Engineering Controls in Ergonomics: A Step-by-Step Guide for Safer Workplaces

When it comes to injury prevention and employee health, few strategies are as effective as engineering controls. Unlike administrative controls (such as rotating shifts) or personal protective equipment, engineering controls focus on redesigning the workplace itself (tools, equipment, and workstations) to better fit the worker.

By addressing ergonomic risks at their source, organizations can reduce injuries, prevent musculoskeletal disorders (MSDs), and create healthier, more productive environments. In this article, we’ll explore the value of engineering controls and explain how any workplace can begin implementing them in five clear steps.

What Are Engineering Controls in Ergonomics?

Engineering controls are physical changes to a workplace or task that affect risk factors contributing to injury. In ergonomics, the focus is on designing the job to fit the worker.

Examples of engineering controls in ergonomics include:

• Mechanical lifting devices to minimize heavy manual handling
• Height-adjustable desks and ergonomic chairs
• Moving bins closer to the employees and reducing reach distances
• Redesigned tools or handles with the ideal diameter to reduce strain on hands and wrists

Because they remove risks at the source, these solutions are considered the most effective form of ergonomic intervention.

Why Are Engineering Controls Valuable?

The benefits of engineering controls go beyond compliance with safety standards. They provide long-lasting improvements that help both employees and employers:

1. Prevent Musculoskeletal Disorders (MSDs): Reducing repetitive strain, awkward postures, and forceful demands helps eliminate common workplace injuries.
2. Improve Productivity and Quality: Comfortable, supported workers perform tasks more efficiently with fewer mistakes.
3. Lower Costs: Fewer injuries mean fewer workers’ compensation claims, reduced healthcare spending, and less absenteeism.
4. Boost Morale and Retention: Employees see ergonomic improvements as a sign the company values their well-being.
5. Provide Sustainable Solutions: Engineering controls become part of the workplace design, benefiting everyone long-term.

Five Steps to Introduce Engineering Controls in Any Workplace

The idea of implementing ergonomic solutions can feel overwhelming, but the process can be broken into five manageable steps. Whether you’re in an office, a warehouse, or a manufacturing plant, these steps apply.

Step 1: Identify Ergonomic Risks

Start by looking for tasks or workstations that involve:

• Repetitive motions: typing, assembly work
• Awkward postures: bending, twisting, reaching overhead
• High force demands: lifting boxes, pushing/pulling, heavy hand tools
• Prolonged positions: sitting at a desk or standing at a machine for hours

Observation, ergonomic checklists, and employee feedback are all tools for identifying workplace risk factors. Workers often know which tasks cause discomfort, so their involvement in this process is essential.

Go in-depth into everything you need to know about the ergonomic risk identification process in our 12-page guide to identifying ergonomic risk factors.

Step 2: Evaluate and Prioritize

Not all risks can be addressed at once, so it’s important to evaluate which hazards have the biggest impact. Look at:

• How many employees are affected?
• How severe is the reported discomfort?
• How high is the quantified risk?

Forming a cross-functional team that includes workers, supervisors, and a safety manager or ergonomist can help ensure the right factors are evaluated when determining priorities.

Step 3: Design and Select Engineering Controls

Once priorities are clear, the next step is to choose the right ergonomic solutions for each situation. Engineering solutions for many common ergonomic risk factors include:

• Adjustable workstations for seated or standing work
• Conveyors to move product instead of manual carrying product
• Mechanical hoists, vacuum lifts, or pallet positioners for heavy loads
• Ergonomically designed tools to reduce hand and wrist strain

It’s important to match solutions to the specific job demands. Buying generic “ergonomic products” without considering their qualities, functionality and benefit may lead to wasted investment. A word of caution: sometimes the description “ergonomic” can be placed onto products to make them more attractive, and also increase the price tag, without necessarily addressing your functional ergonomic needs.

Step 4: Implement and Train

Installing engineering controls is only part of the process. Involving your employees in the brainstorming ensures changes aren’t made to their work areas without their prior knowledge and input. They’ll also need training on how to use the new equipment properly. Clear communication is essential so employees understand the purpose of the changes and how they will enhance comfort and safety.

Encourage feedback at this stage to identify whether adjustments are needed.

Step 5: Monitor and Continuously Improve

Engineering controls require ongoing evaluation. Employers should track:

• Injury and discomfort reports
• Productivity data
• Employee feedback

If problems remain, controls may need to be adjusted or combined with administrative measures, such as task rotation or scheduled microbreaks.

Building a Safer, Smarter Workplace

Engineering controls in ergonomics are more than just “nice-to-have” improvements. These methods act as essential tools for preventing workplace injuries, improving efficiency, and supporting employee well-being.

When work fits the worker, everyone wins.

Got Ergonomics Questions? We’ve Got Answers.

Briotix Health provides ergonomic services and consulting for projects big and small. We help spot potential ergonomic issues in job tasks, measure the level of risk, and offer practical solutions to reduce that risk at scale.

Schedule a 30-minute call with our ergonomics experts to discuss your needs!