Ergonomic Claims Cost Businesses Billions Annually

SAN DIEGO, March 10, 2025 /PRNewswire/ -- Flexible Assembly Systems today announced that musculoskeletal disorders (MSDs), often caused by poor ergonomics, are a significant problem in manufacturing, leading to substantial costs for employers. MSDs account for almost 400,000 injuries per year and one-third of all workers' compensation costs. Indirect costs, such as lost productivity and product defects, can be up to five times the direct costs, bringing the total cost of MSDs to $60-$80 billion annually.

The average cumulative trauma claim cost was $29,000. However, the total cost of a workplace injury can be much higher when indirect costs are considered. For every dollar spent on direct costs, employers can expect to spend an additional $2.12 on indirect costs.

The industries most affected by ergonomic claims are those with a high incidence of manual material handling tasks, such as warehousing and manufacturing. In 2022, the transportation and warehousing sector had the highest serious injury and illness rate of all industry sectors, with an estimated 3.8 cases per 100 workers. Some companies have seen significant cost reductions by implementing ergonomic improvements. For example, American Express Financial Advisors lowered costs by 80%, and Sikorsky accrued over $4.5 million in labor savings.

While the costs associated with ergonomic claims are significant, there are steps manufacturers can take to mitigate these expenses and create a healthier work environment. To prevent ergonomic claims, manufacturers should implement an ergonomic process that includes:

• Providing management support
• Involving workers in identifying and reporting hazards
• Providing training on ergonomics and injury prevention
• Identifying and assessing ergonomic problems
• Implementing solutions to control hazards
• Encouraging early reporting of MSD symptoms to help prevent or reduce the progression of symptoms and the development of serious injuries and lost-time claims
• Evaluating the effectiveness of the ergonomic process

By prioritizing ergonomics and investing in preventative measures, manufacturers can not only protect their employees' well-being but also significantly reduce costs, improve overall productivity, and reduce employee turnover.

About Flexible Assembly Systems
Flexible Assembly Systems is an industrial supply distribution company with a focus on offering ergonomic solutions to manufacturers in the Automotive, Aerospace, Defense, Electronics, and medical device segments. For more information, visit www.FlexibleAssembly.com.

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SOURCE Flexible Assembly Systems Inc