Choose an insurance provider with ergonomic experience, expertise and support
Ergonomics Best Practices in Manufacturing
Advanced Risk Assessment
Look for a carrier that combines ergonomic expertise with innovative technology to help identify hazards, analyze data and recommend the most impactful solutions.
Dynamic Expertise and Resources
Select a partner that offers ongoing support to help ensure that ergonomic controls remain effective as emerging techniques and technology in
Choose a provider that integrates innovative tools and specialized services to assist with streamlining and humanizing the incident response and recovery process and optimizing outcomes.
Slide 1 of 4.
Ergonomics Best Practices in Manufacturing
#1
Design work environments to promote good posture and help reduce strain
Adjustable Workstations
Ensure that workbenches, desks, chairs and other work surfaces can be modified and adjusted to suit the heights and physical needs of different workers.
Ergonomic Tools
Use tools with features like padded grips, lightweight materials, power assistance and other designs that promote neutral postures and minimize manual effort.
Task Arrangement
Minimize unnecessary motions and rotate or spread repetitive tasks throughout the workday.
Encourage employees to take frequent breaks.
Slide 2 of 4.
Ergonomics Best Practices in Manufacturing
#2
Minimize manual lifting and transportation of materials and equipment
Lifting Assistance
Use carts, forklifts, hand trucks, hoists, conveyors or other mechanical devices and technologies to lift heavy materials and equipment.
Smart Storage
Store frequently used and heavy items in areas where employees won’t have to bend or reach to access them. Store them as close as possible to where they will be used.
Automate Transport
Use automated material-handling systems like conveyor belts or automated guided vehicles (AGVs) to reduce manual transportation of materials and equipment.
Slide 3 of 4.
Ergonomics Best Practices in Manufacturing
#3
Engage employees in company end-to-end ergonomics efforts
Ergonomics Training
Provide regular training on ergonomic techniques and tools, including proper lifting protocol, workstation adjustment and stretching routines.
Early Reporting and Intervention
Encourage employees to recognize and report symptoms of ergonomic injuries as soon as they occur. Then provide corrective actions and assistance as soon as possible.
Data-Driven Risk Management
Collect and analyze data to identify safety risks, track injury patterns and make informed, proactive decisions about which ergonomic interventions might have the most impact.
Ergonomic success stories
Reducing muscular impact can help manufacturers minimize common work-related injuries. Travelers has results to prove it.
Manual Shift
A building products manufacturer used Travelers AI-assisted ergonomic tools and specialist analysis to determine that workers manually moving large lumber carts had a “very high” risk of injury.
This prompted the company to make critical
improvements, including:
Adding low-force casters to help reduce the effort required to move the carts.
Adding a raised deck for easier unloading and loading of carts.
Improving floor surfaces.
Switching to smaller loads in the carts.
These efforts reduced the manufacturer’s overall risk index for this task by 66%.*
A Travelers ergonomics professional collaborated with an equipment manufacturers plant team to uncover potential causes of employee musculoskeletal disorders.
Travelers’ practical, cost-effective recommendations helped decrease manual lifting and handling.
“Insurance carriers may typically have some way to help people identify the risk – an app or a wearable – but they often lack the expertise to fix the problem. To unlock effective ergonomic solutions, it’s important to understand how to leverage data and real-world experience to create solutions. This is precisely where Travelers excels – helping manufacturers turn data into actionable improvements that can help decrease the risk of injuries.”
Mary Ellen Ausenbaugh Technical Director, Risk Control - Human Factors and Ergonomics at Travelers
Heavy lift
Tech assist
Travelers’ ergonomics professionals worked alongside an automotive components manufacturer to help determine that installing new conveyance systems could help reduce the amount of material handled by workers and the potential resulting strain. Together, the improvements were implemented, and line employees were trained in the safe, effective operation of the new systems.
As a result, the company reported decreases in key ergonomic risk factors with an added bonus of increased productivity.*
50%
Reduction in manual material-handling frequency.
45%
Overall ergonomic risk reduction based on PAT (Posture Assessment Technique) scores.
How a musculoskeletal disorder (MSD) injury can progress
MSDs can become more severe over time, compounding many of today’s less severe claims into next year’s high-severity trend.
Stage 1
Stage 1
Overuse
Assembly line work, operating machinery and lifting heavy objects can lead to overuse and overexertion of musculoskeletal groups, causing microscopic tears in muscles, nerves, tendons, ligaments and joints.
View Next
Stage 1
Overuse
Stage 2
Fatigue
Without proper time to recover, overworked or damaged muscles, nerves, tendons, ligaments and joints can become fatigued, irritated and weak, making them even more susceptible to damage.
View Next
Stage 2
Fatigue
Stage 3
Ache
The first sign of damage to the musculoskeletal system is typically an ache, which workers often ignore. Continuing job-related tasks can further aggravate microinjuries to muscles, nerves, tendons, ligaments and joints.
View Next
Stage 3
Ache
Stage 4
Pain
If early warning signs, like aches, are ignored, musculoskeletal damage can escalate into more persistent pain as muscles, nerves, tendons, ligaments or joints become increasingly irritated and inflamed.
View Next
Stage 4
Pain
Stage 5
Disorder
Chronic, cumulative musculoskeletal damage causing physical changes may lead to permanent disorders and potentially major workers compensation claims.
As a result, the company reported decreases in key ergonomic risk factors with an added bonus of increased productivity.*
Travelers’ ergonomics professionals worked alongside an automotive components manufacturer to help determine that installing new conveyance systems could help reduce the amount of material handled by workers and the potential resulting strain. Together, the improvements were implemented, and line employees were trained in the safe, effective operation of the new systems.
Tech assist
Reduction in manual material-handling frequency.
50%
Overall ergonomic risk reduction based on PAT (Posture Assessment Technique) scores.
45%
Shorter cycle time to complete the process.
15%
Heavy lift
A Travelers ergonomics professional collaborated with an equipment manufacturers plant team to uncover potential causes of employee musculoskeletal disorders.
Travelers’ practical, cost-effective recommendations helped decrease manual lifting and handling.
Heavy Lift
Manual shift
A building products manufacturer used Travelers AI-assisted ergonomic tools and specialist analysis to determine that workers manually moving large lumber carts had a “very high” risk of injury.
Adding low-force casters to help reduce the effort required to move the carts.
Adding a raised deck for easier unloading and loading of carts.
Improving floor surfaces.
Switching to smaller loads in the carts.
Manual Shift
Home
Quiz
Choose an insurance provider with ergonomic experience, expertise and support
Choose a provider that integrates innovative tools and specialized services to assist with streamlining and humanizing the incident response and recovery process and optimizing outcomes.
Holistic Claim Management
Select a partner that offers ongoing support to help ensure that ergonomic controls remain effective as emerging techniques and technology in
Dynamic Expertise and Resources
Look for a carrier that combines ergonomic expertise with innovative technology to help identify hazards, analyze data and recommend the most impactful solutions.
Advanced Risk Assessment
#4
Ergonomics Best Practices in Manufacturing
Engage employees in company end-to-end ergonomics efforts
Collect and analyze data to identify safety risks, track injury patterns and make informed, proactive decisions about which ergonomic interventions might have the most impact.
Data-Driven Risk Management
Encourage employees to recognize and report symptoms of ergonomic injuries as soon as they occur. Then provide corrective actions and assistance as soon as possible.
Early Reporting and Intervention
Provide regular training on ergonomic techniques and tools, including proper lifting protocol, workstation adjustment and stretching routines.
Ergonomics Training
#3
Ergonomics Best Practices in Manufacturing
Use automated material-handling systems like conveyor belts or automated guided vehicles (AGVs) to reduce manual transportation of materials and equipment.
Automate Transport
Store frequently used and heavy items in areas where employees won’t have to bend or reach to access them. Store them as close as possible to where they will be used.
Smart Storage
Use carts, forklifts, hand trucks, hoists, conveyors or other mechanical devices and technologies to lift heavy materials and equipment.
Lifting Assistance
#2
Minimize manual lifting and transportation of materials and equipment
Ergonomics Best Practices in Manufacturing
Minimize unnecessary motions and rotate or spread repetitive tasks throughout the workday.
Task Arrangement
Use tools with features like padded grips, lightweight materials, power assistance and other designs that promote neutral postures and minimize manual effort.
Ergonomic Tools
Ensure that workbenches, desks, chairs and other work surfaces can be modified and adjusted to suit the heights and physical needs of different workers.
Adjustable Workstations
Design work environments to promote good posture and help reduce strain
#1
Ergonomics Best Practices in Manufacturing
Ergonomics Best Practices in Manufacturing
Home
Quiz
“Insurance carriers may typically have some way to help people identify the risk – an app or a wearable – but they often lack the expertise to fix the problem. To unlock effective ergonomic solutions, it’s important to understand how to leverage data and real-world experience to create solutions. This is precisely where Travelers excels – helping manufacturers turn data into actionable improvements that can help decrease the risk of injuries.”
These efforts reduced the manufacturer’s overall risk index for this task by 66%.*
