Embracing Continuous Improvement: The Essentials of 24/7 Ergonomics Analysis

For those working on the front-line in warehouses and in logistics, one of the biggest workplace health and safety risks relates to the load and time pressures delivery demands place on individuals undertaking manual lifting. 

Unless these workers are given proper training on how to lift items correctly and their movement is continuously monitored to spot poor practices, there is a risk that they can develop musculoskeletal disorders (MSDs).

MSDs, however, are not just caused by the physical strain associated with heavy lifting. Other influencing factors include repetitive movements, such as overstretching when moving items from a shelf at head height to the shop floor, and poor posture while sitting/standing at a poorly-designed workstation, which can be exacerbated if the worker spends extended periods in one position.  

If these physical and repetitive activities are left unchecked, individuals can develop back pain and repetitive strain injuries, including neck, shoulder and wrist problems. 

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This can significantly affect a worker’s mobility and ultimately – because they need more time to complete a task or even time off to rest or recover – employee productivity. 

MSDs can be prevented by making ergonomic improvements to roles that involve physical and repetitive movements or prolonged periods of inactivity. 

What’s more, advances in artificial intelligence (AI) have made it possible to analyse ergonomic movements continuously in real-time, so that adjustments can be made to an employee’s workstation and/or the equipment they operate, minimising MSD risk.

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Benefits of continuous ergonomics monitoring

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Although it is not practicable for managers to physically monitor employees all the time, for example, to check that they are lifting items correctly, AI can be employed for continuous 24/7 ergonomics analysis and in such a way that isn’t intrusive. 

Not only can this be done without infringing employee rights, but it can also be used to improve an employee’s musculoskeletal health while also enhancing safety management across a business. When this happens, injuries are prevented and employee productivity and satisfaction improves. But how exactly is this achieved? 

The answer is through a combination of different ergonomic tools and technology. To start with, once the employee has given their consent, sensors attached to their clothing or on wearable technology can monitor the individual’s movement and changes in their posture. 

This early detection enables managers to track higher-risk procedures, for example, particularly intense activities that are linked with increased MSD risk and identify potential issues in real-time as they happen. 

These data-driven insights are incredibly valuable in finding resolutions because they enable decision-makers to make interventions that can minimise MSD risk, for instance, by adjusting an individual’s workload or introducing rest breaks for very demanding tasks where poor practices could creep in. 

Businesses can also employ smart cameras interlinked with CCTVs on the shop floor that will capture employee activity over the course of their shift. The data captured can help managers to pinpoint when risky practices such as overreaching occur and the findings can be used to improve employee safety training on specific tasks. 

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In this respect, however, it is important managers reassure individuals identified that they are not being singled-out for punishment, but rather that this exercise provides an opportunity to improve their own workplace health through improvements in ergonomic management. 

It is also worth highlighting how AI can be employed to analyse historical data on MSD cases. This is really important because managers can use the insights to predict where future issues may arise so preventative action can be taken.

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Implementing 24/7 Ergonomic analysis

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On top of all the benefits that AI-driven continuous ergonomics monitoring brings, highly advanced workplace safety solutions like Protex AI can be integrated seamlessly into a company’s existing safety programme. 

In addition, the software provider can offer a bespoke service that enables end users to take full advantage of the full range of solutions that the AI system can offer, including identifying poor manual handling processes. EHS teams can then act on this data to personalise training, for example, by highlighting improvements in posture, technique and work habits that will all contribute to reducing the risk of MSDs developing.

In this respect AI can also identify potential weaknesses in existing safety strategies and what remedial action could be taken to strengthen safety management procedures. 

Once employees can see that the training has had a positive and visible impact – there has been a reduction in absenteeism and a turnover in staff – companies will discover that employee morale improves significantly. 

What’s more, when management takes proactive measures to prevent MSD-related injuries, employees will feel more valued; that their welfare is important to senior leaders. The result is that frontline workers then become more active participants in the promotion of a culture of health.

What is clear is that the adoption of 24/7 ergonomics analysis using AI can be truly transformative for businesses. 

Whether it is improved employee health through a reduced risk of MSDs and the improvements in productivity that flows from this, or an enhanced EHS monitoring system driven by data insights that can be used to improve workstation designs and task allocations, the question is: can you really afford not to be without it?   

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