Watchdog report: Exoskeletons and ergo sensors take it on the chin
Manufacturers and warehouses are scrambling to find a solution to prevalent and costly musculoskeletal disorders (MSDs). Are wearable technologies the answer? A new report offers mixed findings. Wearables may provide some benefit to workers suffering pain or discomfort, the report claims. Yet, it also finds limited evidence to support their ability to reduce injuries.
A just-released Government Accountability Office (GAO) report explores wearable technologies in the fight against MSDs. These injuries affect the muscles, nerves, tendons, joints, cartilage, or spinal discs. The Bureau of Labor Statistics (BLS) alleges they result from activities like bending, reaching, twisting, overexertion, or repetitive motion.
High rate/cost of MSDs
MSDs plague employers, according to 2021 to 2022 data from the BLS:
Industry: | # of MSDs with days away from work: | % of MSDs with days away from work for particular industry: |
Private industry | 502,380 | 22.4% |
Manufacturers | 67,400 | 24.8% |
Warehousing | 24,090 | 35.1% |
Construction | 33,240 | 23.0% |
Ergonomic principles recommended
For decades OSHA has urged employers to apply ergonomics principles to solve MSD issues. Ergonomics is the science of fitting a job to a worker.
Looking back, it should be noted that OSHA even issued a final Ergonomics Program rulemaking in November 2000. Shortly thereafter, Congress passed a resolution of disapproval of the standard. OSHA was forced to remove the Ergonomics Program standard from the CFRs in April 2001.
Fast forward to today, OSHA can still use the General Duty Clause (Section 5(a)(1) of the Occupational Safety and Health Act) to cite employers for exposing workers to recognized hazards that cause serious MSDs.
What about wearables?
Wearables have an unfortunate history. In the 1990s back belts were trending at work in hopes of reducing MSDs. Then OSHA issued an April 1998 letter of interpretation declaring, “Back belts are not recognized by OSHA as effective engineering controls to prevent back injury. While they may be accepted by individual workers because they feel as if they provide additional support, the effectiveness of back belts in the prevention of low back injuries has not been proven in the work environment.”
In recent years, manufacturing and warehousing companies have turned to new wearable technologies to help prevent MSDs. According to GAO, the two most-deployed, modern wearables are:
- Exoskeletons — Devices worn around the body to support a worker’s arms, legs, back, hand, or use of tools. Active exoskeletons use battery-powered motors to assist the muscles and augment the strength of the wearer. Passive exoskeletons use springs and dampers to support the wearer.
- Ergonomic sensors — Compact sensors designed to detect postures or motions that could cause injury. They measure the body’s orientation and use algorithms to analyze whether workers enter risky postures.
As interest in wearables grows, questions persist about whether they can “really” reduce injury.
GAO findings
The new report concludes that current data offer limited evidence showing the long-term efficacy of exoskeletons and ergonomic sensors to reduce injuries and improve worker safety:
- GAO examined publicly available studies of deployments of exoskeletons in the field AND in the lab. The agency did not find definitive, measurable safety results in the field. Lab studies, however, offer encouraging data that exoskeletons can reduce muscle strain and may, over time, help prevent injuries.
- GAO looked at studies involving ergonomics sensors. These devices offer diagnostic information about some injury risks. The trouble is the studies have not demonstrated that this information can improve worker safety. Multiple limitations, including sensor accuracy, are the hold up.
When deploying wearables, stakeholders have described challenges related to:
- Comfort and convenience,
- Identifying jobs for wearables,
- Identifying where wearables are a better solution than other controls,
- Limited data on efficacy,
- Data ownership and privacy,
- An evolving market, and
- Worker burdens.
Meanwhile, stakeholders continue to collect data and gather worker feedback. Stakeholders argue they need more time to resolve challenges. National consensus committees too are developing standards to address safe design and manufacture, risk management, and ergonomics.
Wearable regulations?
OSHA does not have regulations for wearables. Still, inspectors may note the use of wearables during a visit. The agency tells GAO that it has not received injury reports directly attributable to wearable use.
GAO’s report cautions that without regulations, wearables could enter the marketplace without safeguards. The report specifically points to safeguards to prevent data abuse or punitive use.
Key to remember
A government report offers mixed findings about the efficacy of wearables. Stakeholders say they need time to resolve challenges.