Test Your Ergonomics Know-How
See Ergonomic Solutions at Work
From process design to distribution, seamless collaboration between people and machines is smart business. Modeling workstations and workflows with ergonomics in mind can help manufacturers maximize worker safety, minimize the financial impact of injuries and optimize operations for success.
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Facts About Workplace Injuries
67
Days of work manufacturing employees missed on average due to workplace injuries.
Strains and sprains
37%
12%
Fractures
The Most Common Injuries in Manufacturing
Inflammation
9%
Dislocations
6%
Contusions
7%
Overexertion
34%
Slips, trips and falls
16%
The Most Common Causes of Injuries in Manufacturing
Being struck by an object
10%
Caught-in or caught-between hazards
Repetitive motion
8%
Our findings
Ergonomic workstations and tools can help increase speed and accuracy and reduce unnecessary motions in manufacturing.
45% reduction in rejected parts
Reduced overall risk index by 66%*
By adding low-force casters to carts and a raised deck for easier, faster loading and unloading, a manufacturer reduced its overall risk index for the task by 66%.
Ergonomic interventions on an assembly line, including improved lighting, led to a 45% reduction in rejected parts.
Boost Productivity and Quality Control
https://www.researchgate.net/publication/245528184_Ergonomics_interventions_improve_quality_in_manufacturing_A_case_study
$49,971
Caught-in/between hazards
$47,076
Struck by an object
$40,104
Average cost of a workers compensation claim for accidents that occurred in 2020 and 2021
$41,757
Reduce Workplace Injuries and Loss Costs
per violation
$16,000
max penalty for repeated violations
$161K
In recent years, manufacturers have faced significant fines for safety violations. These fines can result from issues like insufficient machine guarding, inadequate respiratory protection and lack of proper training.¹
Strengthen Compliance
Employee absenteeism may be reduced by as much as 58% with ergonomic solutions that help prevent fatigue and discomfort.1
In 2022, ~18,000 OSHA inspections were initiated by employees reporting potential hazards.2 Addressing hazards proactively can help increase employee satisfaction.
2022 OSHA inspections
Decrease Employee Absenteeism and Increase Satisfaction
unfulfilled manufacturing jobs due to lack of skilled labor is projected by 2030.1
2.1M
of manufacturing employers have hiring challenges that they anticipate will extend to the future.1
77%
fabrication workers are needed for the U.S. to become self-sufficient in chip manufacturing.2
~300K
Reduce Vulnerability to Talent Shortages
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Quiz
2024 Travelers Injury Impact Report
*Based on Travelers proprietary risk rating scale, AI-Enhanced Ergonomic Assessments, Feb. 2021-Feb. 2022
https://injuryfacts.nsc.org/work/costs/workers-compensation-costs/
1https://www.osha.gov/news/newsreleases/trade/01112024
2https://www.osha.gov/enforcement/2022-enforcement-summary
1https://www.ergocenter.ncsu.edu/ergohowl_q2_2021/
1https://nam.org/2-1-million-manufacturing-jobs-could-go-unfilled-by-2030-13743/.
2https://www.csis.org/analysis/reshoring-semiconductor-manufacturing-addressing-workforce-challenge
Reduce Vulnerability
Employee Absenteeism
Strengthen Compliance Absenteeism
Reduce Injuries
Productivity and Quality Control
Injury Facts
ERGONOMICS INSIGHTS: SAFE WORK IS SMART BUSINESS
Designing secure and efficient work environments for workers of all shapes, sizes, needs and abilities can help keep employees safer – and be good for business.
Designing secure and efficient work environments for workers of all shapes, sizes, needs and abilities can help keep employees safer – and be good for business
Ergonomic interventions on an assembly line including improved lighting, led to a 45% reduction in rejected parts.
45% Reduction in rejected parts
Reduced Overall Risk Index By 66%*
Unfulfilled manufacturing jobs due to lack of skilled labor is projected by 2030.1
MENU
https://www.researchgate.net/publication/245528184_Ergonomics_ interventions_improve_quality_in_manufacturing_A_case_study
1https://nam.org/2-1-million-manufacturing-jobs-could-go-unfilled-by -2030-13743/.
2https://www.csis.org/analysis/reshoring-semiconductor-manufacturing -addressing-workforce-challenge
Conclusion
Best Practices
Success Stories
Musculoskeletal Disorder
Ergonomic Insights
CLOSE
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.
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
View Next
Stage 4
Pain
Stage 3
Ache
Stage 2
Fatigue
Overuse
Stage 5
Disorder
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.
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.
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.
Chronic, cumulative musculoskeletal damage causing physical changes may lead to permanent disorders and potentially major workers compensation claims.
https://www.cdc.gov/workplacehealthpromotion/health-strategies/musculoskeletal-disorders/index.html
Manual Shift
Ergonomic success stories
Reducing muscular impact can help manufacturers minimize common work-related injuries. Travelers has results to prove it.
Tech assist
Heavy lift
Manual shift
*Based on Travelers proprietary risk rating scale, AI-Enhanced Ergonomic Assessments, Feb. 2021 - Feb. 2022
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.
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%
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
“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
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%.*
Travelers’ practical, cost-effective recommendations helped decrease manual lifting and handling.
A Travelers ergonomics professional collaborated with an equipment manufacturers plant team to uncover potential causes of employee musculoskeletal disorders.
“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 decrease the risk of injuries” Mary Ellen Ausenbaugh Technical Director, Risk Control - Human Factors and Ergonomics at Travelers
This prompted the company to make critical improvements, including:
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.
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 advanced manufacturing are implemented.
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
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
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
Minimize unnecessary motions and rotate or spread repetitive tasks throughout the workday. Encourage employees to take frequent breaks.
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
Travelers’ video risk assessment tools can help customers harness the power of their company’s front-line data to better understand and manage workforce risk. Our industry-leading workers compensation programs can provide the expertise, experience and data manufacturers need to help proactively reduce the impact of work-related injury claims.
For more information, contact your insurance agent or a Travelers representative.
Invest in the right workers compensation insurance partner
Our industry-leading workers compensation programs can provide the expertise, experience and data manufacturers need to help proactively reduce the impact of work-related injury claims.
Travelers’ video risk assessment tools can help customers harness the power of their company’s front-line data to better understand and manage workforce risk.
Test your ergonomic know-how
Understanding the impact ergonomics can have on your manufacturing business and operations is the first step in helping to protect your workers and your bottom line.
Insights
When evaluating manual material-handling tasks, which of the following ergonomic risk factors should be minimized?
1/3
Task variety
Task complexity
Task duration
Next Question
Correct!
The duration of time spent completing manual material- handling tasks is directly proportional to the risk of related ergonomic injuries. Limiting the frequency, length and intensity of manual material lifting and transportation activities may reduce the risk of worker injuries.
Incorrect!
https://ehs.oregonstate.edu/sites/ehs.oregonstate.edu/files/pdf/ergo/ergonomicsanddesignreferenceguidewhitepaper.pdf
The duration of time spent completing manual material-handling tasks is directly proportional to the risk of related ergonomic injuries. Limiting the frequency, length and intensity of manual material lifting and transportation activities may reduce the risk of worker injuries.
Which body part do manufacturing workers most commonly injure?
2/3
Fingers
Shoulders
Lower Back
Shoulders are the most commonly injured body part among manufacturing workers. But ergonomic solutions to limit or assist in the manual lifting of heavy objects, pushing and pulling of carts, material handling and more may help reduce overuse and overexertion that can lead to shoulder injuries.
https://asset.trvstatic.com/download/assets/travelers-injury-impact-report.pdf/b6befc8063d211eeb3e29e98f6b6ed6a
Increased productivity
Improved efficiency
Missing critical risk factors
Get Results
Analyzing data without specialized ergonomics knowledge can result in missing key hazards, potentially leading to significant workplace injuries, increased operational downtime and costly workers compensation claims.
3/3
What is one potential downside of analyzing ergonomics data yourself?
You answered 0 of 3 questions correctly!
Question 1
Question 2
Question 3
Implementing impactful end-to-end ergonomic solutions starts by knowing the risks and understanding how to mitigate them. Travelers offers industry-leading innovative ergonomics services, solutions and expertise that can help prevent ergonomic injuries from impacting business productivity and profitability.
You answered 1 of 3 questions correctly!
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