In the fast-paced world of manufacturing, your team’s well-being is a huge part of your company’s success. Common aches, pains, and strains can easily lead to lower productivity, more sick days, and higher workers’ compensation costs. An ergonomics assessment checklist for manufacturing is one of the best tools you can use to get ahead of these problems and create a safer, more efficient workplace.
What is an Ergonomics Assessment Checklist for Manufacturing?
An ergonomics assessment checklist for manufacturing is a structured tool designed to evaluate workstations, tasks, and equipment to minimize the risk of musculoskeletal disorders (MSDs). These disorders, such as carpal tunnel syndrome, tendonitis, or back pain, are common in manufacturing due to repetitive tasks or improper workstation setups. The checklist ensures a thorough review of the workplace by covering several critical areas, as outlined in resources like OSHA’s ergonomic guidelines.
| Category | Checklist Items | Details/Thresholds |
| Health History | Previous diagnoses of MSDs (e.g., carpal tunnel, tendonitis, back ailments) | High risk if diagnosed and no fixes; medium risk if changes made |
| Worker Complaints | Reports of discomfort or pain related to work tasks | High risk if combined with two other risk factors; medium risk with one other factor |
| Repetition | High repetition tasks (100 reps/hour to 2000/day) | High risk if combined with two other risk factors; medium risk with one other factor |
| Lifting | Routine heavy lifting (>20 lbs) or occasional heavy lifting (>50 lbs) | High risk if six or more risk factors present; medium risk with three to five factors |
| Tool Design | Awkwardly designed tools causing non-neutral positions (>1 hour) | High risk if six or more risk factors present; medium risk with three to five factors |
| Posture – Head/Neck | Awkward head/neck position for extended time (1-3 hours) | Optimal: 0°-10°; Moderate: 10°-15°; Severe: 15°-20° |
| Posture – Back | Awkward back angles (hunching, bending) for extended time (2-3 hours) | Optimal: 0°-5°; Moderate: 5°-10°; Severe: 10°-15° |
| Posture – Elbows | Awkward elbow angle for extended time (1-3 hours) or extreme force | Optimal: 90°-105°; Moderate: 105°-120°; Severe: 120°-135° |
| Posture – Wrists | Awkward wrist flexion/extension for extended time (1-3 hours) or extreme force | Optimal: 0°-15°; Moderate: 15°-30°; Severe: 30°-40° (flexion), 35°-45° (extension) |
| Reaching | Extreme reaching distance for extended time (1-3 hours) or extreme force | Optimal: Male 10”-15”, Female 8”-12”; Severe: Male >20”, Female >16” |
Each category is assessed with yes/no questions, and risk levels (high, medium, rlow) are determined based on the number of risk factors present. For instance, heavy lifting combined with awkward postures and repetitive tasks may indicate a high-risk workstation requiring immediate intervention.
Why is an Ergonomics Assessment Important in Manufacturing?
The physical demands in manufacturing, from repetitive motions to heavy lifting, can lead to painful and expensive musculoskeletal disorders (MSDs). Putting a good ergonomics assessment program in place brings some very practical advantages.
Fewer Workplace Injuries
Ergonomic reviews help you find and fix workplace hazards, like a poorly designed station or the wrong tool for the job. This allows you to stop chronic problems such as back pain and tendonitis before they ever have a chance to develop.
Better Productivity and Quality
When your team is comfortable, they can work more effectively. Proper ergonomics reduces physical fatigue, helping employees keep a steady pace and maintain their focus. This naturally leads to higher output and fewer mistakes, improving the quality of your products.
Stronger Employee Morale
Investing in ergonomics sends a clear message that you care about your people’s well-being. When employees see their feedback about physical discomfort leads to real changes, it builds a foundation of trust and respect that boosts satisfaction and team engagement.
Real Cost Savings
You’ll see significant financial returns from a solid ergonomics program. It helps lower direct costs, such as workers’ compensation claims, along with the many indirect costs of injuries like lost workdays and administrative burdens.
A Culture of Proactive Safety
Regular assessments help your company move from simply reacting to injuries to actively preventing them. It encourages everyone to participate in spotting risks, making safety a shared responsibility that’s built into your daily operations.
How to Conduct an Ergonomics Assessment in a Manufacturing Setting
A thorough ergonomics assessment involves several steps. It’s not just about walking through the facility with a clipboard. A comprehensive approach includes:
- Reviewing Injury and Illness Logs: Start by examining your OSHA 300 logs and other internal records to identify any trends or patterns in injuries. This will help you pinpoint high-risk departments or job tasks.
- Engaging with Employees: Your workers are the experts on their own jobs. Talk to them about their discomforts, challenges, and any suggestions they have for improvements. Questionnaires and informal interviews can be very effective.
- Observing the Work: Watch employees perform their tasks in their natural work environment. Pay close attention to their postures, movements, and the tools they use. Video recording can be a useful tool for later analysis.
- Utilizing an Ergonomics Assessment Checklist: A checklist provides a structured framework for your assessment, ensuring you don’t overlook any potential hazards. It helps to standardize the process and provides a clear record of your findings.
- Analyzing the Data and Implementing Solutions: Once you have gathered all the information, analyze it to identify the root causes of any identified risks. Then, develop and implement practical solutions. These can range from simple adjustments, like raising a work surface, to more significant investments in new equipment.
What to Include in an Ergonomics Assessment Checklist for Manufacturing
A good ergonomics assessment checklist for manufacturing should be comprehensive yet easy to use. It should cover the key risk factors associated with manufacturing tasks. Here is a sample checklist, modeled after established guidelines, that you can adapt for your facility:
Ergonomics Assessment Checklist – Manufacturing
Date:
Department/Area:
Job Task Assessed:
Assessor:
| Risk Factor | Yes | No | Notes/ Observations |
| A. Repetitive Motion | |||
| 1. Does the task involve repeating the same motion every few seconds? | |||
| 2. Is the task performed for more than two hours per day? | |||
| B. Forceful Exertion | |||
| 3. Does the task require lifting objects weighing more than 20 lbs? | |||
| 4. Does the task involve pushing or pulling heavy loads? | |||
| 5. Are workers required to use a pinch grip to handle objects? | |||
| C. Awkward Postures | |||
| 6. Does the task require working with the hands above the head or the elbows above the shoulders? | |||
| 7. Does the task involve bending or twisting the back or neck for extended periods? | |||
| 8. Are workers required to kneel, squat, or crawl? | |||
| 9. Are the wrists bent or deviated while performing the task? | |||
| D. Contact Stress | |||
| 10. Do any tasks or tools press into the worker’s palms, fingers, or other body parts? | |||
| 11. Are there any sharp or hard edges on work surfaces or equipment that workers come into contact with? | |||
| E. Vibration | |||
| 12. Does the task involve the use of vibrating hand tools (e.g., grinders, sanders, impact wrenches)? | |||
| 13. Do workers stand on vibrating surfaces for long periods? | |||
| F. Workstation and Tool Design | |||
| 14. Is the work surface at an appropriate height for the worker and the task? | |||
| 15. Are tools and materials within easy reach, minimizing excessive reaching? | |||
| 16. Are the tools used appropriate for the task and do they have ergonomic handles? | |||
| 17. Is there adequate lighting for the task being performed? | |||
| 18. Is there sufficient space for workers to move and change positions? | |||
| G. General | |||
| 19. Have there been any employee complaints of pain or discomfort related to this task? |
This checklist provides a starting point. You can and should customize it to address the specific hazards present in your facility.
Promote Your Workplace Wellbeing with Ergo Global
For businesses seeking to enhance workplace ergonomics, Ergo Global provides comprehensive assessment services tailored to both manufacturing and office environments. Our certified ergonomists conduct 30-minute virtual or in-person assessments, delivering personalized solutions for each worker.
| Service Type | Duration | Description | Benefits |
| Virtual Ergonomics Assessments | 30 minutes | 1-on-1 video call assessments for remote or dispersed teams | Detailed report, improvement plan, follow-ups, equipment procurement |
| In-Person Ergonomics Assessments | 30 minutes | 1-on-1 in-office assessments for fixed-desk workers | Detailed report, improvement plan, follow-ups, equipment procurement |
Our process begins with an inquiry through our website, followed by planning and executing team assessments. Each employee receives a risk score, a detailed improvement plan, and access to ergonomic equipment from a pre-approved list. Regular follow-ups ensure sustained benefits, and we prioritize data safety, using information solely for internal purposes.
Ready to invest in your team’s well-being and boost your bottom line?
Contact Ergo Global today to schedule your expert ergonomics assessments.
