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In the industrial world, the task typically takes priority. Everything, from plant layout to equipment design, is engineered to refine the process, squeeze out efficiencies, and boost output. Unfortunately, this means that work is mostly designed around what needs to be done rather than who is doing it.
Industrial ergonomics centers on reversing this standard, finding ways to adapt the task and the work environment to the worker, helping to reduce injuries, elevate wellbeing and morale, and boost overall business efficiency.
In this article, we delve deeper into the definition of industrial ergonomics, why it’s important, and what it looks like in practice.
Industrial ergonomics – At a glance
- Industrial ergonomics focuses on adjusting industrial workstations and tasks to suit workers, reducing physical demand and minimizing risk factors.
- In practice, industrial ergonomics aims to reduce the potential for harm by improving posture, limiting repetitive motions, and easing physical strain placed on workers.
- Industrial ergonomics is essential to reduce musculoskeletal disorder (MSD) rates among workers in industrial roles. By doing so, it can significantly improve worker productivity and business profitability.
- Effectiveness requires a strong safety culture, staff training, and continuous improvement.
What is ergonomics?
When discussing industrial ergonomics, perhaps it makes things easier to understand to first consider ergonomics in isolation. In simple terms, ergonomics is the science of making work safer for workers.
The dictionary defines ergonomics as follows:
‘The scientific study of people and their working conditions, especially done in order to improve effectiveness.’
As this definition suggests, ergonomics focuses on understanding how people interact with their work environment and using that understanding to make improvements. In practice, ergonomics involves two key elements:
- Gathering data – This means studying how people perform their tasks, the tools and equipment they use, their posture, movements, and the physical or cognitive demands of their work. It’s about observing, measuring, and identifying where strain, inefficiency, or risk may occur.
- Taking action – Once the data is collected, it’s used to design or modify systems, tools, and processes to better fit the people who use them. This might involve adjusting workstation layouts, introducing assistive devices, or redesigning workflows to reduce fatigue and injury while boosting productivity and comfort.
What is industrial ergonomics?
If ergonomics is about designing work to fit people, industrial ergonomics takes that principle and applies it to the demanding environments of factories, warehouses, and production lines.
Think of a worker lifting heavy components all day or twisting repeatedly to reach tools. Each small motion might seem harmless, but over time, those repetitive strains can add up — leading to fatigue, discomfort, and sometimes injury. Industrial ergonomics is the science (and the practice) of reducing those physical demands.
It’s about designing tasks, tools, and workspaces so that people can perform their jobs safely, efficiently, and comfortably. This might mean:
- Adjusting the height of a workbench to reduce bending and reaching.
- Redesigning a handle to improve grip and minimize wrist strain.
- Reorganizing workflow so that materials move smoothly through a process instead of forcing workers to overexert themselves.
The goal isn’t just to prevent injury — it’s to make work smarter. When tasks require less unnecessary effort, workers can focus more on precision and productivity. The result is a workplace that supports both human health and operational performance.
Why industrial ergonomics matters in the modern workplace
In today’s industrial workplaces, from warehouses to manufacturing plants, the need for effective ergonomics has never been greater.
MSDs are common and cost the economy
MSDs remain one of the most common and costly workplace injuries in the United States, accounting for roughly 30% of all cases that result in time away from work¹. These injuries typically stem from repetitive motions, awkward postures, or heavy lifting — all of which are everyday realities in industrial environments.
More than half of American adults (around 124 million people) report living with a musculoskeletal condition². In economic terms, occupational MSDs alone cost the U.S. around $50 billion per year³.
MSDs are expensive for businesses
For employers, the consequences are felt directly: each repetitive motion injury can cost an average of $40,000⁴ when factoring in medical treatment, compensation, and lost productivity.
Reviewing the latest Bureau of Labour Statistics reports, roughly 35-40% of occupational MSDs occur in industrial work environments, meaning businesses in industrial verticals, such as manufacturing and construction, are disproportionately impacted.
Learn about the top 3 causes of MSDs in construction.
Find out how poor ergonomics undermines smart manufacturing.
Beyond the numbers, poor ergonomics can negatively impact morale, retention, and operational reliability. When employees are in pain or fatigued, productivity declines, quality suffers, and absenteeism rises.
Conversely, when workstations, tools, and tasks are designed to fit the worker, rather than forcing the worker to adapt, people perform better. They experience fewer injuries, recover faster, and stay longer in their roles.
Prevent MSDs with Cardinus
We offer a range of industrial ergonomics services to help business owners protect staff health and wellbeing across a variety of non-office environments – including:
- FlashAI – Motion capture app for any smartphone or tablet, accompanied by AI risk analytics
- Healthy Working Pro – End to end industrial ergonomics platform; a complete solution for industrial ergonomics risk – Enquire today
- Onsite industrial ergonomics support – Contact us
Industrial ergonomics and employers’ duty of care
Under U.S. law, employers have a legal and moral duty to provide a workplace that is safe and free from recognized hazards. OSHA’s General Duty Clause states that organizations must take all reasonable steps to protect workers from injury and illness — including those caused by poor ergonomic design.
That said, the effectiveness of industrial ergonomics relies on shared responsibility. Employers can implement the best equipment, tools, training and processes, but workers also play a crucial role in making them work. When employees actively participate by following safe practices, using ergonomic supports, and reporting issues early, the system functions as intended.
The main aspects of industrial ergonomics
Industrial ergonomics focuses on identifying and controlling the physical risk factors that lead to strain and injury. In most industrial settings, these can be grouped into four key areas: posture, force, frequency, and environmental conditions.
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Posture
When workers are required to bend, twist, or reach awkwardly, stress builds in the back, shoulders, and neck. Over time, poor posture is one of the most common causes of musculoskeletal disorders.
How ergonomics helps: Adjustable workstations, height-appropriate benches, and tools designed for comfort help maintain neutral body positions. For instance, tilting assembly tables or using height-adjustable platforms can greatly reduce the need for bending and stretching.
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Force
Tasks that require high physical effort — lifting, pushing, pulling, or gripping tightly — increase the likelihood of injury. Even small tools can create strain if they require excessive hand force.
How ergonomics helps: Introducing lifting aids such as hoists, conveyors, or trolleys minimizes the effort workers need to exert. Tools with ergonomic handles and proper leverage also reduce hand and wrist strain.
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Frequency and repetition
Repetitive tasks, even those requiring little force, can still cause fatigue and overuse injuries. Holding a fixed position for long periods has a similar effect, placing continuous stress on specific muscle groups.
How ergonomics helps: Job rotation, micro-breaks, and automation of repetitive motions all help distribute workload and give muscles time to recover. Encouraging movement throughout a shift keeps workers more comfortable and alert.
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Environmental conditions
Temperature, lighting, and noise all influence how safely and comfortably a person can work. Cold environments, for example, can reduce dexterity and grip strength, forcing workers to apply more effort.
How ergonomics helps: Maintaining appropriate ambient temperatures, providing insulated or breathable PPE, and ensuring good lighting and noise control all support sustained comfort and safe performance.
Protect your industrial workforce with Healthy Working Pro
Cardinus helps organizations reduce risk and improve worker safety through smarter ergonomics.
Healthy Working Pro is our comprehensive industrial ergonomics software, streamlining assessments with automated data collection, real-time analysis, and customizable tools built for industrial environments. Inquire about Healthy Working Pro today – or contact the team to discuss your needs.
