In industrial settings, injuries can be devastating—both to the health and well-being of workers and the productivity of operations. While many safety programs focus on personal protective equipment (PPE) or emergency procedures, one powerful and proactive approach to injury prevention is often overlooked: ergonomics.
Ergonomics is the study and science of people in their working environment. This applies to anywhere anyone is working – thus ergonomics can apply in a factory setting on a conveyor line, or to a remote worker behind a desk. In industrial environments, ergonomics takes the form of shaping jobs and tasks to match the physical and cognitive capabilities of workers. From lifting and repetitive motions to tool handling and machine operation, applying ergonomic principles help reduce fatigue, discomfort, and the likelihood of musculoskeletal injuries caused by poorly designed tasks or environments.
Injury prevention starts even before someone is hired. Pre-hire screening that includes a job analysis can ensure that new employees are physically capable of performing job tasks safely. By evaluating the demands of a specific job—such as lifting requirements, sustained postures, or fine motor tasks—employers can use pre-employment testing, like a POET (Post-Offer Employment Test) to place candidates in roles that align with their abilities. This step significantly reduces the risk of injury from overexertion or mismatch between worker capabilities and job demands.
Example: A warehouse employer may screen candidates to confirm they can safely lift 50 pounds multiple times per hour, in an effort to prevent back injuries caused by assigning lifting tasks to those that are unprepared for the activity. By testing for specific job demands with objective results, hiring remains equitable and fair as well.
Once employees are hired, task assignment plays a major role in injury prevention. Task assignment ensures that job duties are distributed in a way that minimizes exposure to repetitive strain, awkward postures, or forceful exertions. Limiting or redesigning high-risk activities, or assigning physically demanding jobs to trained personnel with the right tools and techniques can prevent overuse injuries.
Practical Steps: Depending on the task, using height adjustable workstations can allow employees of different sizes to perform the same task comfortably and safely—reducing shoulder, neck, and lower back strain.
Training programs that incorporate ergonomic best practices are essential for building a culture of workplace safety. Ergonomics-focused safety training equips employees with the knowledge and tools to perform tasks safely, recognize ergonomic hazards, and respond to discomfort before it leads to injury. When combined with body mechanics training employees are better equipped to do the job right, and respond quickly when something is going wrong.
In high-risk environments, simulation-based training can also help employees learn how to move safely in confined spaces or handle awkward loads without injury.
Ergonomic workplace design is one of the most effective long-term strategies for preventing industrial injuries. By engineering safety into the work environment, risks can be minimized before a task even begins. This includes:
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Daily safety techniques, when supported by ergonomic principles, can make a big difference. These include:
These steps help reinforce safe practices and promote early intervention when discomfort begins, rather than waiting for injuries to occur.
A large number of these techniques are also supported now by ergonomic software solutions. Whether that is pinging employees every 30 to 45 minutes to take a microbreak, guiding employees through pre-shift warmups, or using analytic software to adjust workloads, software can be a robust solution. Having control over your own program and being able to see in real-time the cause and potential effects of injuries is a game-changer for risk management.
Sign up for an easy demo of ErgoPlus Industrial software if you want to learn more about how injury prevention and risk management software can help you take the power away from injuries at work..
The use of tools designed to reduce strain and improve posture plays a supporting role. Examples include:
When used correctly, these tools can extend worker endurance and reduce exposure to risk factors. They should not be applied without thought though. Ergonomic tools should be used in tandem with an ergonomic program to support the goals and objectives set out in planning. Over reliance on tools without identifying the systems they are supporting can balloon costs when simple ergonomic solutions could solve the problem.
Industrial injuries don’t just happen—they are often the result of a mismatch between a worker and their task or environment. Ergonomics provides a structured, science-based way to close that gap. From the moment a worker is hired through every step of their daily routine, ergonomic principles can guide decisions that protect health, reduce risk, and improve performance.
By embracing ergonomic strategies across all stages—pre-hire, task assignment, training, workplace design, and daily safety practices—employers can create a safer, more productive workplace where injuries are the exception.