Preventing musculoskeletal injuries: eleven common employer mistakes
According to the National Safety Council (NSC), musculoskeletal disorders (MSDs) are the most common and among the costliest workplace injuries. Liberty Mutual's latest Workplace Safety Index shows "overexertion involving outside sources" (lifting heavy loads) cost employers $12.49 billion a year, awkward positions ("other exertions or bodily reactions") cost employers $3.68 billion, and "repetitive motions involving microtasks" cost employers $1.54 billion. Work-related MSD cases result in 38 percent more time away from work than other injury types.
Sedentary postures at computers, highly repetitive motions, lean operations increasing the demands on workers, an aging workforce, and inconsistent preventive programs have contributed to the rise of such injuries. These injuries can affect workers in any industry, not just those in physically demanding roles. Yet, they are largely preventable.
Prevention is the most cost-effective approach to MSD injuries. By avoiding these eleven common mistakes and taking a comprehensive, proactive approach, employers can significantly reduce the risk of workplace injuries and improve their workforce's overall health and safety.
- Take a reactive, fragmented approach
A spike in injury rates triggers urgency, and the employer implements some corrective action, such as a stretching program or training on lifting, but once the injuries decline, the focus diminishes. Proactive ergonomic assessments identify potential risks before injuries happen, allowing for workspace or process modifications that have a lasting effect on preventing employee pain, long recovery times, and productivity loss. - Overreliance on external expertise
Professional ergonomists play a critical role in observing workers, evaluating workplaces, processes, and equipment, and designing systems that help employees work smarter and safer. However, relying solely on the specialist's analysis and recommendations without gathering input from employees with firsthand operations experience or fostering workers' understanding of ergonomic principles is a path to failure. An effective ergonomics program is a continuous improvement process requiring staff and leadership input and participation. - Address symptoms and not the root causes
Offering back braces or stretching programs might temporarily ease discomfort. Still, they don't fix poor workstation ergonomics, unrealistic workloads, or inadequate training that lead to musculoskeletal strain, which can morph into costly claims. - Focus on only the obvious risks
MSDs are multifaceted and can have several contributing factors. Chronic pain, repetitive strain injuries, and even psychological distress can develop gradually and may not be immediately evident. An effective prevention program requires a proactive process to identify and assess all obvious and hidden hazards. It's crucial to perform a detailed analysis of job tasks to understand the physical requirements and potential risks. - Fail to do post-offer employment testing (POET)
POET helps employers determine whether job candidates can safely perform required physical tasks before placement, reducing injury risk. Baseline testing also establishes a worker's range of motion, strength, and movement capabilities, providing valuable comparative data when injuries occur. - Lack of job rotation or task variation
Repetitive tasks without rotation or recovery time increase the risk of injury. Switching tasks helps reduce overuse injuries. - Offer ineffective treatment to workers
In the meat-processing industry where MSD risks are prevalent, a common practice is to offer first-aid treatment such as ice, over-the-counter pain medication, and tape to workers experiencing MSD pain. Such treatment can mask discomfort, causing workers to aggravate the injury and worsen the condition, leading to lost productivity, days away from work, and a costly claim. Effective MSD management requires a comprehensive approach that includes early intervention, ergonomic adjustments, physical therapy, and employee training. - Neglect valuable data
Injury reports and near misses offer essential insights into areas requiring company-wide improvements. Using this data can inform strategy and be used to evaluate the results of corrective actions. - Inadequate recovery-at-work programs
Bringing someone back to work without properly designed, modified tasks can worsen injuries and prolong recovery. Physical therapists can implement specialized return-to-work programs such as work conditioning, which builds stamina and work-specific capabilities to ensure successful job reintegration. - Don't start with a pilot program
When implementing ergonomic solutions, verifying that they reduce risk, have not introduced new risks, and do not make the worker's job harder is critical. After thorough assessments of workstations, tasks, and employees are complete, implement the interventions in a specific department or group of workstations to test the program. Focus on high-impact ergonomic tools and solutions that provide a good return on investment. Provide ergonomics training to employees and management to help them understand ergonomic principles and recognize potential problems. Monitor the program's effectiveness by measuring injury rates, productivity, and employee satisfaction. Adjust as needed, update work instructions, provide employee training, and apply to all jobs with similar risks across departments and locations. Continue to evaluate and make necessary adjustments to ensure the solutions remain effective. - Fail to balance individual and company-wide ergonomic solutions
Indeed, ergonomics is not a one-size-fits all. Every employee is different and adjustable furniture, ergonomic accessories, specialized equipment, and training should be tailored. But this is not enough to address larger systemic issues related to workstation design, tools, or work processes. Consider addressing common ergonomic risks across the organization and then move on to personalized solutions as needed.