9 MSD Injury Prevention Techniques for Manufacturing Environments

Musculoskeletal disorders (MSDs)—such as back pain, shoulder impingement, tendinitis, and carpal tunnel syndrome—are some of the most common and costly injuries in the manufacturing sector. These soft tissue injuries are caused or exacerbated by repetitive motion, awkward posture, excessive force, vibration, and prolonged static positions—risk factors frequently found in industrial workplaces.

Unlike acute injuries from slips or cuts, many MSDs develop over time. The slow onset of musculoskeletal injuries makes them harder to identify early, but their impact is long-lasting: lost productivity, restricted duty assignments, absenteeism, and higher healthcare costs.

The good news is most MSDs are highly preventable with targeted strategies. Here are 9 essential techniques manufacturing employers can implement to prevent MSD injuries and support a healthier, safer workforce.

Jump to section:

1. Ergonomic Material Handling Strategies
2. Tool and Equipment Ergonomics
3. Environmental Design and Layout Optimization
4. Targeted Training on MSD Risk Factors
5. Smart Hiring and Pre-Placement Screening
6. Early Discomfort Reporting and Onsite Triage
7. Continuous Ergonomic Risk Assessment
8. Engineering Controls and Ergonomic Retrofits
9. Culture of Prevention and Employee Engagement

1. Ergonomic Material Handling Strategies

Manual material handling is a primary contributor to MSDs. Whether workers are lifting, pushing, pulling, or carrying loads, the biomechanical stress can accumulate quickly without proper controls.

Expert Recommendations:

• Redesign tasks to reduce unnecessary lifts and reaches.
• Provide height-adjustable pallet lifts, turntables, and tilt bins to keep materials in the safe lifting zone (between mid-thigh and mid-chest).
• Use mechanical assist devices like hoists and conveyors to reduce force demands.
• Train workers on team lifting and lifting with proper mechanics.

2. Tool and Equipment Ergonomics

Using hand tools or powered equipment that don’t fit the task or the user can lead to overuse injuries in the hands, wrists, shoulders, and elbows.

Best Practices for MSD Prevention:

• Select tools with ergonomic handles—non-slip grips, reduced vibration, and appropriate handle diameters.
• Eliminate pinch grips and awkward wrist positions with tools designed to align with neutral posture.
• Reduce tool weight or counterbalance when static holding is required.
• Implement anti-vibration gloves or padding for tools like grinders and impact wrenches.

3. Environmental Design and Layout Optimization

A poorly designed workstation forces workers into poor posture or repetitive reaching. Thoughtful environmental setup reduces unnecessary physical stress and supports neutral alignment.

Effective Adjustments Include:

• Organize parts, tools, and controls within the primary reach zone (14–18 inches from the body).
• Provide adjustable workbenches, chairs, and platforms to accommodate workers of different heights.
• Avoid overhead work and static forward bending by raising or rotating fixtures.
• Use lighting that reduces glare and visual strain, minimizing awkward head and neck positioning.

4. Targeted Training on MSD Risk Factors

Training shouldn’t stop at general safety protocols—it must be specific to MSDs and tailored to the tasks employees perform.

Training Should Cover:

• Early signs and symptoms of MSDs.
• Proper lifting mechanics and body positioning.
• Task-specific ergonomics (e.g., how to adjust a fixture or maintain neutral posture during a repetitive task).
• Stretching routines or microbreak protocols designed for the muscle groups used in specific job roles.

5. Smart Hiring and Pre-Placement Screening

Some MSD risks are predictable based on the physical demands of the job. Integrating job demands into hiring helps align the job with the right person and identifies risks early.

Preventative Tactics:

• Use validated physical demand testing (e.g., post-offer employment testing) to confirm an applicant can safely perform essential tasks.
• Base testing on detailed job demands analyses to ensure legal defensibility and accuracy.
• Assess functional movement patterns that may indicate higher risk for strain or poor biomechanics.

6. Early Discomfort Reporting and Onsite Triage

One of the most effective ways to prevent minor discomfort from turning into an OSHA-recordable injury is early reporting and intervention.

MSD-Focused Solutions:

• Implement discomfort survey tools or digital self-reporting apps.
• Train employees to recognize and report symptoms before they become injuries.
• Provide access to onsite or near-site clinicians who can perform early intervention, soft tissue management, and stretching protocols.
• Empower supervisors to respond quickly to discomfort reports with workstation or task adjustments.

7. Continuous Ergonomic Risk Assessment

Ergonomic risks evolve as tasks, tooling, or production demands change. Ongoing assessments ensure risks are caught early and eliminated before injuries occur.

Assessment Approaches:

• Conduct routine ergonomic risk assessments focused specifically on ergonomic risk factors like posture, force, and frequency.
• Score tasks using industry recognized tools like the Rapid Upper Limb Assessment (RULA) or NIOSH Lifting Equation to quantify risk and prioritize areas for improvement.
• Use video analysis and motion capture tools to quantify movement and assess awkward posture.

Watch a quick demo of how ErgoPlus Industrial can make computer vision assessments fast and easy for anyone to complete!

8. Engineering Controls and Ergonomic Retrofits

When risk is high the most effective solution can be the introduction of an “engineering control”. An engineering control is a strategy designed to protect workers from hazardous conditions. This includes physical changes to the workstation or equipment to eliminate the root cause of strain.

Examples of Engineering Fixes:

• Add adjustable height platforms or anti-fatigue mats for standing workstations.
• Retrofit work surfaces with tilt mechanisms to reduce neck flexion.
• Introduce automation or assistive devices for high-force, repetitive tasks.
• Design fixtures to eliminate the need for manual holding or clamping.

9. Culture of Prevention and Employee Engagement

MSD prevention is most effective when workers feel ownership over their health and understand how their daily choices affect long-term well-being.

Build Engagement By:

• Encouraging worker input in ergonomic redesigns and process improvements.
• Recognizing and rewarding safe behaviors and early reporting.
• Embedding wellness and movement into the workday with stretching programs and microbreaks.
• Including ergonomics and wellness in onboarding, safety talks, and toolbox meetings.

MSD Prevention Is Strategic, Not Accidental

Manufacturing environments face unique physical demands, but musculoskeletal injuries are not an inevitable part of the job. Through targeted ergonomic interventions, hiring practices, engineering solutions, and worker training, organizations can drastically reduce the risk and cost of MSDs.

Investing in MSD prevention leads to:

• Lower workers’ compensation claims.
• Improved productivity and morale.
• Longer, healthier careers for employees.

If you’re ready to assess your MSD risk exposure or implement an ergonomics-focused injury prevention program, consult with a qualified ergonomist or injury prevention specialist to begin building your solution.