Reducing Workplace Injuries in Manufacturing: The Role of Onsite Early Intervention Services

How can EI specialists help prevent injuries and illnesses at work?

• By Kyle Schmoyer, CSP
• Apr 24, 2023

Workplace injuries can have devastating consequences for both employees and employers. Lost productivity, medical costs and even long-term disabilities can result from workplace injuries, leading to increased insurance premiums and decreased worker morale.

The risk of workplace injuries is exceptionally high in the manufacturing industry, where manual labor is often required. However, studies have shown that workplace onsite early intervention (EI) services can be an effective tool to help reduce workplace injuries. This article explores why that may be and delves into a recent study on the subject that makes a compelling argument for implementing workplace EI services.

Work-Related Musculoskeletal Disorders

Work-related musculoskeletal disorders (WMSDs) affect muscles, nerves, tendons, joints, cartilage and spinal discs, and they occur when work conditions significantly contribute to or worsen the state. Examples of WMSDs include lifting heavy objects, repetitive forceful tasks, daily exposure to whole-body vibration, work with the neck in a chronic flexion position or routine overhead work.

Positive evidence links work conditions to musculoskeletal disorders (MSDs) of the neck, shoulder, elbow, hand, wrist and back. According to the Bureau of Labor Statistics (BLS), in 2020, the private sector had 247,620 injuries or illnesses related to MSDs that required time off work. In addition, MSDs are costly to employers due to absenteeism, lost productivity, and increased healthcare, disability and worker's compensation costs.

Companies can take several steps to prevent WMSDs. One approach is to implement ergonomic principles into the design of workstations, tools and equipment to reduce awkward postures, forceful exertions and repetitive motions. Employers can also provide training and education to employees on proper lifting techniques, good posture and stretching exercises. Many companies decide to take a comprehensive approach, demonstrated by the growing popularity of onsite early intervention services.

The Value of Onsite Early Intervention Services

Onsite EI services refer to a comprehensive approach to employee wellness and safety that involves having a trained specialist available at a facility or worksite. This service aims to provide immediate care and ergonomic analysis to employees experiencing discomfort or pain. In addition, the EI specialists work proactively with employees and employers to identify and resolve the root cause of any discomfort or pain, ultimately preventing any injuries or illnesses from occurring in the workplace.

One of the critical components of onsite EI services is proactive engagement, which includes ergonomic assessments, employee education and job demand analysis. Through these activities, EI specialists can identify areas in the workplace that may cause discomfort, such as repetitive motions, heavy lifting or prolonged sitting.

They can also assess the work environment, including lighting, temperature and noise levels, to ensure they meet the necessary standards. Additionally, they can provide education and training on proper posture, stretching techniques and ergonomics, which can help prevent future injuries.

Onsite EI services can also include preventative activities such as new hire training, stretching programs and wellness interactions. These activities aim to prevent injuries from occurring in the first place and promote employee wellness.

For example, new hire training can ensure that employees know proper work techniques and ergonomics from the start while stretching programs can help prevent muscle strains and other injuries. In addition, wellness interactions can include health fairs, flu shot clinics and other health-promoting events.

Another critical component of onsite EI services is reactive intervention, which involves responding to employee discomfort and providing immediate care. This aspect of the service ensures that employees receive prompt and appropriate care, reducing the likelihood of the condition worsening.

EI specialists provide OSHA-approved first aid and referrals to appropriate medical care when necessary. They also work with the employees and employers to create return-to-work plans to ensure a smooth transition back to work following an injury or illness.

Overall, onsite EI services are an effective tool for preventing workplace injuries and promoting employee wellness. The proactive and reactive components of the service, along with preventative activities, ensure that employees receive comprehensive care and support. By identifying and resolving the root causes of discomfort and pain, onsite EI services can help prevent injuries and illnesses, ultimately reducing medical costs and improving employee productivity.

What Data Says About EI

Atlas Injury Prevention Solutions published a paper titled "Onsite Early Intervention Services, Age, and Injury Rates within Manufacturing" to measure outcomes and compare injury rates of manufacturing companies with EI programs to BLS averages.

In terms of injury rates, the data showed statistically significant improvements for companies with better than industry-average Total Recordable Incident Rates (TRIR) as their EI programs mature. The data demonstrated a strong positive correlation between EI services and decreased injury rates, with participants seeing a 29 percent improvement between the first and second years of EI services.

One reason for these results may be that traditional, reactive interventions to discomfort or musculoskeletal injuries fail to address the root cause. In contrast, onsite EI specialists work proactively with the employee and employer to review work methods and identify the root cause of the discomfort with ergonomic assessments, employee education and job demand analysis.

The data from the Atlas study also showed that proactive interactions were critical in preventing injuries from happening in the first place. The onsite EI specialists took measures, such as new hire training, stretching programs and wellness interactions, to prevent injuries. These interactions and activities with employees focused on improving their overall health and wellness, reducing the likelihood of them developing musculoskeletal issues.

To understand the impact of proactive interactions on injury rates, the study analyzed two specific data points: total annual proactive activities and total ergonomic or proactive solutions generated by the EI specialist. The findings showed that companies with a better-than-average TRIR rate exhibited a 53 percent increase in interactions with EI specialists than those with a worse-than-average TRIR rate.

Moreover, the study broke down the data to the number of contacts per hour onsite to better understand the effectiveness of proactive interactions. The analysis revealed that companies with a better-than-average TRIR rate had three times as many proactive connections with their employees on average.

The most significant interaction within the data was solutions generated by the onsite EI specialist and implemented by the client companies. The study found that companies with decreased injury rates demonstrated a 3.4 increase in solutions developed or implemented. This significant correlation demonstrated the importance of assessing the potential issues for injury and the benefit of collaboration between the onsite provider and company leadership.

The data demonstrates that the most effective EI programs include preventative activities in their onsite services to lower injury rates and improve employee safety. Therefore, companies must focus on developing and implementing more ergonomic solutions through job demand analyses, ergonomic risk assessments and individual employee interactions.

For Companies Seeking Continuous Improvement

Workplace onsite EI programs, uniquely tailored to address the specific needs of a company's workforce, play a crucial role in bolstering safety and minimizing injury rates. A compelling correlation between these services and a decline in workplace injuries has been observed. Notably, organizations with better than average TRIR experience 53 percent more engagement with EI professionals than those with worse rates.

Considering this evidence, businesses need to prioritize the incorporation of onsite EI specialists, as this strategy can significantly mitigate injury rates, medical expenses and health-related attrition. Moreover, the value of onsite EI services in injury prevention and reducing injury rates continue to expand. Therefore, companies must commit to investing in these initiatives and collaborate closely with EI experts to secure the best outcomes for their employees and financial performance.