Some workstations have a reputation that everyone knows about.
“This is the toughest station on the production line.”
“After two hours here, my shoulder starts hurting.”
“New employees never want to stay at this station.”
Over time, these comments almost become normal.
Yet when a task regularly causes pain, fatigue or complaints among the people performing it, it’s worth asking an important question: Should the worker really have to adapt to the workstation, or should the workstation itself be reassessed?
That’s exactly where ergonomics comes in.
In industrial environments, ergonomic risks can be associated with repetitive movements, manual material handling, excessive physical exertion, awkward postures and work organization.
Over time, these demands can contribute to the development of musculoskeletal disorders (MSDs).
And these problems don’t always begin with a sudden injury. Often, the first warning signs appear much earlier.
Here are seven signs to watch for.
- Several Employees Report Pain at the Same Workstation
One employee experiencing back pain doesn’t automatically mean a workstation is poorly designed.
But if three, four or five people performing the same task all complain about pain in their back, shoulder or wrist, that’s a different story.
The work itself becomes something worth investigating.
Pay particular attention to:
- The movements being performed
- How frequently those movements are repeated
- The force required
- The working height
- Arm positioning
- Twisting movements
- The distance required to reach tools or materials
- Opportunities for recovery between physical efforts
Employee feedback is often one of the best starting points for an ergonomic assessment.
After all, they’re the ones performing the work every day.
- A Position Is Difficult to Fill… or Nobody Wants to Stay in It
Employee retention challenges aren’t always strictly human resources issues.
Sometimes, they’re also ergonomic issues.
If a workstation is known to be particularly physically demanding, employees frequently ask to be reassigned, or new workers don’t stay in the position for long, it may be worth examining the physical demands associated with the job.
Is the pace of work extremely fast?
Do employees constantly have to lift or move materials?
Is the same part of the body being used throughout most of the shift?
These are important questions to ask.
Making a workstation less physically demanding can help reduce the risk of injury while also making the job more sustainable over the long term.
- The Same Movement Is Repeated Over and Over
Repetitive movements are common in industrial environments.
Pick up a part. Turn it. Position it. Tighten a screw. Release.
Then repeat.
The movement itself isn’t necessarily the problem. What makes the difference is often how frequently it’s performed, how long it continues, how much effort it requires and how much recovery time is available.
Depending on the task, several solutions may be considered:
- Rearranging the placement of parts and materials
- Changing a tool
- Automating part of the process
- Reducing the physical effort required
- Introducing greater task variety
- Implementing job rotation
Training on MSD prevention can help managers and employees recognize these risk factors before they become a serious problem.
- Job Rotation Is in Place, but Employees Still Use the Same Muscles
Consider this example.
An employee spends two hours at a workstation that places significant strain on their shoulders.
They then move to another workstation… only to perform a different task that puts just as much strain on their shoulders.
Technically, job rotation has taken place.
Physically, however, there has been very little recovery.
Effective job rotation should provide meaningful variation in physical demands, including the muscle groups used, postures, force, repetition and work pace.
This important detail can easily be overlooked when rotation schedules are designed solely around operational requirements.
- Employees Are Required to Work in Awkward Postures
Take a few minutes to observe how the work is actually performed.
Does an employee have to reach forward every time they pick up a part?
Do they regularly work with their back bent forward?
Are their arms constantly raised?
Do they have to twist their body to place a product?
Do they need to stand on their toes to reach something?
Individually, these movements may seem harmless.
But when they’re repeated hundreds of times a day, the physical strain adds up.
Sometimes, simply moving a container, adjusting the height of a work surface or bringing a tool closer can significantly reduce exposure.
In other situations, a more substantial redesign of the workstation may be necessary.
That’s precisely what a workstation ergonomic assessment is designed to do: observe actual working conditions and identify the most appropriate corrective measures.
- Injuries and Absences Keep Occurring in the Same Departments
Your organization may already have valuable information that can help identify ergonomic risks.
Review reported pain and discomfort, first aid records, absences, functional limitations and workplace injuries.
Do certain teams stand out?
Certain tasks?
Certain parts of the body?
A particular workstation?
Even when individual incidents don’t seem alarming, looking at them collectively may reveal a pattern.
An ergonomic assessment then becomes a proactive prevention tool rather than a response to another injury.
When an organization notices recurring problems, specialized consulting services in musculoskeletal disorder prevention can help identify and assess the different factors contributing to the situation.
- Despite Training, You Constantly Have to Remind Employees to Use Proper Postures
“Bend your knees.”
“Keep your back straight.”
“Be careful with your shoulder.”
“Try doing it differently.”
These recommendations can be useful.
But they have an important limitation: if the workstation naturally forces an employee into an awkward posture, even the best intentions won’t change the physical layout of the job.
Consider equipment positioned too low.
You can remind an employee a hundred times not to bend forward, but they still need to reach the equipment.
The same applies to lifting techniques. Employees can be repeatedly reminded to bend their knees and lift with their legs rather than their backs. However, if a task requires them to perform the equivalent of 100 squats throughout the day, they may not have the physical capacity to consistently maintain the recommended technique.
In that situation, adjusting the workstation may be a much more effective solution than repeatedly reminding employees how to move.
An ergonomic approach therefore focuses on reducing risks at the source whenever possible.
How Can Ergonomic Risks Be Corrected?
A common misconception is that ergonomic improvements always involve purchasing expensive new equipment or completely redesigning a production line.
That’s not necessarily the case.
Solutions can include:
- Adjusting workstation height
- Relocating frequently used materials
- Modifying a tool
- Automating a repetitive task
- Changing how work is organized
- Revising employee job rotation
- Modifying the sequence of operations
- Providing employee training
In some cases, more significant investments may be necessary, such as:
- Installing mechanical lifting or handling equipment
- Completely redesigning a workstation when required
The right solution always depends on how the work is actually performed.
What Does an Ergonomist Do During a Workstation Assessment?
An ergonomist does more than check whether an employee is positioned correctly.
Their goal is to understand the task as a whole, including how employees adapt their methods to operational constraints within the organization.
They examine factors such as:
- What the employee actually needs to do
- The movements and physical effort involved
- How frequently movements are performed
- The equipment and tools used
- Workspace limitations
- Work organization
- Differences between established procedures and how tasks are actually carried out
That last point is particularly important.
On paper, a task may appear perfectly reasonable.
In reality, employees often develop their own ways of working to deal with production demands, equipment limitations, insufficient space or certain steps in a process.
Observing these real-world conditions is often what leads to the most effective solutions.
Professional ergonomics consulting services provide an external, specialized perspective on a workstation, task or work environment.
When Should You Request an Ergonomic Assessment?
You don’t need to wait until a workplace injury occurs.
An ergonomic assessment may be appropriate when you notice:
- Recurring pain or discomfort
- Multiple complaints associated with the same workstation
- Highly repetitive tasks
- Significant physical demands
- Positions that are difficult to fill or retain employees in
- An increase in absences or workplace injuries
- The development of a new workstation or production line
- Major changes to an existing process
In fact, the best time to consider ergonomics is often before a problem turns into an injury.
Start by Observing the Work
If you’re not sure where to begin, start with something simple.
Go out onto the floor.
Observe a workstation for 15 minutes.
Talk to the person working there.
Ask them:
“What is the most physically demanding part of your job?”
Their answer might surprise you.
Santinel helps organizations identify and prevent ergonomic risks through specialized training and consulting services in ergonomics and musculoskeletal disorder prevention.
Our experts can assess your workstations and work methods, identify risk factors and recommend practical solutions adapted to your workplace.
Concerned about a particular workstation? Talk to our team.
Frequently Asked Questions About Ergonomic Risks
What is an ergonomic risk?
An ergonomic risk is a workplace condition that may place excessive strain on the body, such as repetitive movements, awkward postures, significant physical exertion or tasks that allow insufficient recovery time.
How can you tell if a workstation presents a risk of musculoskeletal disorders (MSDs)?
Recurring pain, complaints from multiple employees, repetitive movements, awkward postures and physically demanding tasks are all potential warning signs. An ergonomic assessment can provide a more detailed evaluation of the physical demands associated with the workstation.
Does job rotation help prevent musculoskeletal disorders?
Job rotation can help reduce exposure to ergonomic risk factors, but only when the tasks are sufficiently different to allow the muscles and joints to recover.
When should you consult an ergonomist?
Consulting an ergonomist may be appropriate as soon as recurring pain, employee complaints, significant physical demands or workstation-related difficulties are observed.
There is no need to wait until an injury occurs.
In Québec, ergonomic risks should also be assessed as part of your organization’s mandatory occupational health and safety risk assessment, in accordance with the requirements introduced by the Act to modernize the occupational health and safety regime.
