October 10, 2024 How AI Enables Fast, Accurate Ergonomic Assessments

Safety professionals can decrease worker injury by bringing their ergonomics assessments into the 21st century with AI and computer vision.

BY Matt Jeffs, DPT PSM REAS

Musculoskeletal disorders (MSDs) developed as a result of overexertion or slips, trips and falls cost employers a staggering $20 billion annually. That encompasses direct costs like medical care, physical therapy and rehabilitation; and indirect costs, like lost productivity, workers’ comp claims, increased insurance premiums and more.

While ergonomic evaluations can help to lower these costs, it’s important for safety personnel to evaluate what type of evaluation will ultimately be most beneficial.

Traditional ergonomics evaluations and their drawbacks

Traditional pen-and-paper ergonomic assessment tools can take upwards of 40 steps to complete. The mental energy required to utilize these tools adds to more than just the time factor. The upfront cognitive load of delivering a traditional assessment impacts problem-solving, and ergonomists often face fatigue before they even begin to consider potential solutions.

Traditional ergonomics evaluations also involve validating the interventions by reperforming the initial assessment for comparison.

Many ergonomists and EHS professionals who reach this stage are exhausted from dealing with just one ergonomic problem – and all the effort that the pen-and-paper method required. This can lead to a ‘one-and-done’ mindset and approach that is often ineffective in a constantly-changing work environment. Ergonomists and EHS professionals often handle multiple cases simultaneously, further dividing their attention and resources.

However, seasoned ergonomists know that ‘silver bullet’ solutions are rare as are ‘bullseyes’ on the first attempt. Most often, effective interventions require multiphase, multifactorial interventions that create lasting changes to an organization’s safety culture; they also demand significant time, attention and effort from busy EHS professionals.

How AI streamines the ergonomic evaluation process

AI streamlines the multi-step process to a simple point-and-shoot task using a smartphone, reducing the time from upwards of half an hour to mere seconds. This preserves mental energy and cognitive resources. Ranking risks is faster and allows for quicker response times.

AI tools expedite the problem-solving process by instantly providing suggestions, allowing for more iterations and layered interventions. They also ensure a more efficient, thorough approach to solving ergonomic issues and make the cost of retrying much lower and far easier.

Finally, AI enables quick iterations and fast turnarounds; if initial interventions prove less-than-effective, the cost of re-evaluation is minimal, as is the cost of retrying with new solutions.

This flexibility encourages experimentation and adaptation to the ever-changing workplace environment, and the absence of significant sunk costs allows for continuous improvement and responsiveness.

Benefits of AI-driven ergonomic solutions to employees

In addition to benefiting safety professionals, incorporating AI into ergonomics evaluations benefits frontline workers through reduced workplace injuries; increased productivity and efficiency; and improved long-term health.

Reduced workplace injuries

With MSDs and other work-related injuries mitigated via AI-enhanced assessments, there’s a lower need for medical treatment; a lower rate of absenteeism due to injury; fewer workers’ comp claims; lower insurance premiums; and lower costs to train replacement workers.

Increased productivity and efficiency

Improvements in workplace design, tools and processes make tasks easier and safer, thereby increasing efficiency and employee well-being and lowering the chance of absenteeism. Additionally, the time it takes to complete tasks and minimize errors is decreased, resulting in lower operational costs and higher productivity.

Long-term health benefits

Finally, preventing chronic conditions like carpal tunnel syndrome and back pain lowers long-term healthcare costs, and older workers can maintain their health and productivity, which ultimately reduces healthcare and disability costs over time.

Benefits of AI-driven ergonomic solutions to employers

AI-driven solutions offer similar benefits to employers as they do for the workers themselves.

Reduced healthcare costs

By continuously monitoring and analyzing employee movements and postures, AI systems can identify risks and provide real-time feedback to correct potentially harmful behaviors before they lead to injuries.

This early intervention leads to fewer medical claims and lower healthcare expenses. Businesses save on direct medical costs and associated expenses, which is critical in industries with high injury rates like construction and manufacturing.

Improved employee retention

By creating personalized workstations that adapt to individual employees’ needs, AI-driven ergonomics systems can improve comfort and reduce physical strain.

The result is higher employee morale and lower turnover rates. Further, retaining experienced employees reduces recruitment, hiring and training costs. High retention rates preserve institutional knowledge and maintain productivity levels, contributing to overall financial stability.

Increased productivity

By analyzing workflow patterns and suggesting improvements to optimize task performance, AI-driven ergonomic assessments minimize unnecessary movements and reduce physical strain.

Optimized workflows increase efficiency and reduce downtime caused by fatigue or injury, leading to greater output and profitability. Additionally, reducing the physical demands on employees can extend their career longevity, maximizing the return on investment in their training and development.

Proactive risk management

AI-driven systems can predict potential ergonomic issues and recommend proactive measures to mitigate risks.

Consequently, businesses can avoid costly disruptions and maintain continuous operations. Predictive analytics enhance safety, ensure compliance with occupational health standards and assist in avoiding fines or legal expenses. This proactive approach can significantly reduce the financial burden associated with workplace injuries.

The bottom line

By implementing an AI-driven ergonomics solution, employees can see a reduction in workplace injuries; increase their productivity; and see improvements in their long-term health. Businesses can avoid disruptions, maintain operations and ensure compliance.

Matt Jeffs is Education Director at TuMeke, whose AI-driven platform streamlines assessing and mitigating workplace musculoskeletal risks. For additional information, email info@tumeke.io.

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