By Mary Dunlap, CIH Ergonomics, defined simply, is fitting a job to a person to reduce the risk of strains and injury to muscles, tendons, and ligaments, also known as musculoskeletal disorders (MSDs).  The human costs are the best reason for preventing MSDs, but the financial burden to businesses cannot be underestimated. A 2018 survey of days away from work from the U.S. Bureau of Labor Statistics determined that 30 percent of cases were due to MSDs and that MSD cases require 38 percent more lost time days than typical injuries and illnesses. The direct costs associated with a sprain, strain, or hernia type injury can cost a business between $28,000 and $32,000 for medical treatment to resolve the injury.  However, the medical costs are only part of the story and do not include indirect costs such as work stoppage, overtime, training of new employees, legal costs, and increased insurance premiums.

What are the benefits of ergonomics programs?

In addition to keeping workers healthy, there are many added benefits to implementing an ergonomics program that ultimately can make a business more profitable and attractive to potential business partners, highly qualified new employees, and outside investors, including:
        • Reduced costs associated with treating MSDs
        • Reduction in lost workdays and the length of long-term absences
        • Lower employee turnover and costs associated with replacing an employee
        • Higher employee engagement and focus on work quality
        • Increased productivity and efficiency
        • Reduced costs for correcting defects
        • Creating a safety record that is attractive to lenders and outside investors
When ergonomics is regarded as an important part of the operational process, employee engagement is enhanced, as is productivity and work quality.  When an employer places value on the ability to perform the job comfortably and efficiently, employees feel respected.  From this respect, workers are much more likely to be engaged in their work.  With this engagement, comes regard for the quality of work they produce and a willingness to participate in improving processes and performing the work more efficiently.  It has been estimated that even a simple improvement can result in a one-percent increase in quality and a five-percent increase in productivity.  As attention to detail increases, the defect rate goes down and, with that, the costs for correcting the defects. Safety and sustainability have become very important aspects of how companies operate and are key environmental, social, and governance (ESG) indicators that lenders and investors consider when assessing business performance, assigning corporate credit ratings, and considering new investment opportunities.  It is common practice for investors and lenders to request disclosure of injury rates.  The top 29 companies that have earned safety culture awards have been found to consistently outperform the S&P 500 stock index.

What are the risks of workplace injuries? 

The major risk factors for musculoskeletal disorders are:
      • forceful exertions involving with lifting, lowering, carrying, pushing, and pulling
      • repetitive movements, encountered when job cycles are less than 30 seconds long and when the cycle is repeated two or more times in a minute
      • awkward postures that result from poor equipment or the workspace design, not having the right tool to perform a job, and lack of worker awareness of how to properly move and position their body when performing a task.
Of these factors, the Occupational Safety and Health Administration (OSHA) has estimated that 25 percent of non-fatal occupational injuries result from forceful exertions primarily associated with material handling. The costs associated with treating MSDs can be significant when an injury occurs.  Such injuries often result in multiple trips to a doctor or clinic, physical therapy appointments, and even surgery.  In addition to treating the injury, lost workdays and sometimes long-term absences create staffing issues which increase overtime costs and losses in production.  Additionally, job duties sometimes require modification to accommodate an employee who has been injured. When job tasks remain at risk for injury, there are not only lost workdays directly related to injuries but often there is also an increase in “casual absenteeism”.  When strains or injuries are common, workers simply do not want to do the job.  As dissatisfaction increases, so does the rate of employee turnover and the costs for replacing an employee.  On average, it costs a business 20-50 percent of an employee’s salary to find and train a new employee replacement.

What is included in an ergonomics program?

Ergonomics programs and tools can make a big difference in the comfort, safety, and well-being of workers as well as add money to your bottom line?  Actions can range from the simple to the complex and may include:
        • Implementing a daily stretching program for employees
        • Frequently rotating workers that perform repetitive jobs during a shift
        • Providing work surfaces that are the right height for the job
        • Reducing reach distances for parts or tools
        • Providing the right tools and equipment such as lift assist devices
        • Designing new workstations and equipment to best fit workers and their job tasks.
        • Coach and train employees how to properly position their bodies when lifting and performing tasks to avoid strains and injuries.

Further information

Cornerstone’s Health and Safety department can perform a Worksite Analysis to observe operations, job tasks, and work practices for ergonomic safety.  As a Certified Industrial Hygienist, I can provide reports of risks, prioritize areas for changes, and recommend control measures.  Contact Cornerstone at info@corner-enviro.com or on our website https://www.cornerstone-ehs.com/contact-us/ for more information. Mary Dunlap, CIH, is a Senior Industrial Health and Safety Specialist and Certified Industrial Hygienist.  She works with Cornerstone’s clients to develop exposure assessment strategies tailored for their work environments.  She regularly performs ergonomic assessments using a variety of OSHA and NIOSH tools to rate severity of risk for work related to musculoskeletal disorders.
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