There is a big difference between a demanding shift and a dangerous one. Manufacturing jobs can be inherently physical, but hard work shouldn’t double as an injury risk. With the manufacturing sector averaging more than 300,000 manufacturing injuries each year, there is clear room for improvement.
But what risk factors should be prioritized and how do you implement change, especially when the physical effects of the job are very gradual?
As we approach the 30th anniversary of National Safety Month in June, it is the perfect time to evaluate how to reduce risk factors on the factory floor. We will first start with ergonomics and how daily wear-and-tear can lead to the quiet onset of a musculoskeletal disorder (MSD).
Work-related MSDs make up a third of all non-fatal workplace injuries, but many are preventable through early detection and making ergonomics adjustments. We’ll explore the following topics in this ergonomics guide:
Many manufacturing floors still reward toughing it out, which means workers will frequently hide minor discomfort due to professional pride or fear of slowing down the line. They may also misjudge the risk and mistake a serious, repetitive strain for regular fatigue.
According to OSHA, ignoring these early signs is exactly how severe injuries begin. Unlike a slip and fall or sudden machine malfunction, ergonomic injuries build up quietly over weeks, months, or years. Typically, they occur from the following:
A mild, occasional ache in the wrist or shoulder can quickly turn into persistent tingling, numbness, and chronic pain. Waiting until discomfort becomes unbearable and a recordable injury creates a disruptive ripple effect:
A still common misconception in manufacturing is that safety protocols and ergonomic adjustments slow operations down. In reality, the exact opposite is true. To understand why, consider the relationship between physical strain and mental fatigue.
When an operator’s workstation forces them to bend weirdly or awkwardly stretch to reach something, their muscles have to work harder. This makes them more tired faster. Tiredness leads to exhaustion and their cognitive sharpness drops. They are more likely to make mistakes or be less aware of their surroundings.
Implementing ergonomic solutions helps reduce physical fatigue, ensuring workers have more energy, are more focused, and commit fewer mistakes. By designing work environments to fit the person rather than the person fit the work, the production line naturally runs smoother and faster.
From BPA’s Safety Team: “Ergonomics helps to cut down on fatigue, allowing employees to make less mistakes and have more energy while working. Managers can listen to their employees' common complaints and search for ergonomic solutions to help employees’ workday.”
As the Safety Team indicated, managers are the first line of defense against repetitive strain injuries and listening is their greatest tool. Managers must look out for patterns in employee behavior and listen closely to common complaints. Workers should feel empowered to voice their concerns openly.
If an operator mentions that a certain movement is difficult, or if a team leader notices that multiple workers are struggling with the same task, floor managers should treat these complaints and instances as red flags signaling that a process needs to be re-evaluated.
A great example of low-investment, high-impact ergonomics happened right within our own operations when we took a closer look at the fabrication department. The lathe section was initially tightly configured, limiting operator movement. We reorganized the entire section to open up more walking room, which also allowed our teammates to use the material transport carts much more easily. This small change removed a repetitive lifting hazard and improved operator comfort.
Floor management can help solve day-to-day complaints and ensure operators are adequately trained, but long-term hazard elimination often requires an engineering fix. At BPA, when we notice that several people are struggling with a task, or when we partner with customers to evaluate their secondary packaging lines, we look to solve ergonomics issues fundamentally through smart machine design.
When we design our case packers and robotic systems, we aim to eliminate awkward reach or bend points entirely before the machinery ever arrives at a customer’s facility. Here are some of the ways BPA approaches ergonomics in the design process:
This National Safety Month, let's encourage our teams to speak up about minor discomforts before they have a chance to become chronic injuries. MSDs don’t happen overnight, but their effects can last for years, disrupting both a worker's life and a plant’s productivity. By creating a continuous loop of listening to workers and proactively implementing layout and machine fixes, you can build a safer, more efficient floor.
Want to learn more about how our ergonomics can support your safety culture? Contact us today to discuss your line and floor layout.