For ergonomic injuries, fix the cause, not just the symptoms
A good friend who helps employers with ergonomic challenges recently mentioned that many of his clients hire physical therapists to treat ergonomic injuries, but still need help to identify and address the root causes of the injuries. The solutions aren’t necessarily expensive, but failing to identify the cause will commonly result in future ergonomic injuries.
He shared a story about a woman with a shoulder injury who was undergoing therapy and treatment. The employer hired my friend to investigate the cause. He discovered that a big part of her job involved driving Phillips screws, but the driver bit on her tool was worn down, so she had to apply extra force, which strained her shoulder. The solution to eliminating this excess strain was simply replacing the driver bit more frequently.
He also commonly encounters knee injuries to forklift drivers. One cause is that the step to enter a forklift is about 18 inches high, and regularly stepping up or down at the equivalent of two (or more) stair risers causes knee strain. Forklift operators should use three points of contact and pull themselves up, but they still primarily rely on leg muscles. This can be a particular problem for shorter or overweight operators.
Dismounting the forklift repeats the problem in reverse, or the operator jumps down, causing further strain on the knees. While adding a step to a forklift may not be practical, using proper mounting and dismounting technique is essential to minimizing the risk of knee injuries.
For related information, see our article, How to get your workers to identify ergonomic risk factors.
How much is too much?
We then discussed a question that we’ve both been asked many times, “how much weight can an employee safely lift?” There is no simple answer because numerous factors affect the determination, including the capabilities of the person doing the lift. Other factors include:
- The frequency of lifts, such twice per day or 200 times per day;
- Whether the load can be easily grasped, such as bags versus boxes; and
- The starting and ending heights, since lifting from the floor is more difficult than starting at knee or waist height.
Additional considerations include the carrying distance, weight distribution within the load, and size of the load (affecting whether the load’s center is close to the body). Tools like the NIOSH Lifting Equation can help evaluate risk, but the first step should be evaluating engineering solutions that reduce or eliminate the inherent risks. In other words, the first step should be identifying potential risks that could be addressed before an ergonomic condition begins to develop.
Reviewing jobs for repetitive motion, lifting, grasping, vibration, and other risk factors can help employers identify risks. Some jobs do require repetitive motions, so employees and supervisors should immediately report any discomfort that might indicate a developing ergonomic condition. When those reports come in, the employer should not only take steps to address the employee’s symptoms, but should evaluate the job to identify and mitigate the conditions causing those symptoms.


















































