Advances in automation and the relentless drive to increase production are taking a toll on workers and putting their safety at risk. Employees in logistics, manufacturing, food and beverage, and retail sectors face increased risks as they balance the pressures of increased production demands and preservation of their physical health.
Overwork can cause workers to suffer from a number of diseases and disorders of the musculoskeletal system that impact their quality of life and, in some cases, their ability to continue working. Injuries also take a toll on businesses, with more than 264 million working days are lost every year due to back pain. Musculoskeletal injuries caused by repetitive motion can have a significant impact on company productivity, morale and profits. As companies look for ways to protect their workers and improve operational efficiency, wearable technology, particularly exosuits, is emerging as an innovative solution to mitigate these risks while actually improving both worker productivity and their quality of life.
The impact of injuries on productivity
Musculoskeletal disorders (MSDs) are among the most common workplace accidents in the logistics and warehousing sectors. The financial impact of accidents on companies therefore also plays an important role. According to Mutual Freedom Work safety index 2024employers spent more than $1 billion per month in 2021 on direct costs of worker overexertion injuries involving outside sources. As a result, overuse injuries are costing U.S. businesses $12.49 billion.
These injuries don’t just come from moving heavy objects. Although heavier objects can impact stress levels, much of the stress comes from simply supporting the weight of the worker’s upper body during numerous high-frequency bending and lifting cycles. In the food logistics sector in particular, repetitive bending and lifting movements are performed thousands of times per day for order pickers. Employers who adopt safety and health programs can expect a reduction in workplace injuries and associated costs such as workers’ compensation, medical expenses and lost productivity.
Reduce injuries with Exosuits
Many companies in the logistics and warehousing industries are turning to wearable technology like exosuits to protect worker well-being. The exosuit is an innovative wearable technology designed to facilitate demanding physical work. They provide physical support by reducing strain from repetitive tasks, such as lifting or bending. Adoption is growing rapidly, where some studies show 81% of workers respondents wanted to continue using the wearable device after weeks of use.
Studies and user surveys have shown that exosuits can reduce worker fatigue and muscle strain by up to 40%. Some lightweight exosuits can mimic the biological muscles of the back, offloading physical stress from crucial muscle groups and allowing workers to perform repetitive tasks with less strain and fatigue.
In a dynamic workplace, a good exosuit maximizes flexibility and assistance without restricting movement or adding unnecessary weight. For warehouse workers, wearable exoskeleton technology should feature a lightweight, non-motorized design that provides ergonomic support without restricting worker movement or requiring additional power sources and weight. These types of exosuits use passive mechanisms, such as elastic bands, and have been shown to be as effective, and often more effective, than motorized models in relieving tension from crucial muscle groups, particularly the lower back.
Exosuits reduce muscle fatigue and the risk of injury, and their light weight allows workers to wear them comfortably. If the exosuit has a low-profile design, as some do, it can even be used with other PPE, which is especially important in cold storage facilities where protective equipment is required.
Increase worker productivity and well-being
Although the primary goal of exosuits is to reduce the risk of injury and improve worker safety, these devices have also been shown to have a positive impact on productivity. International food retailer surveyed workers who wore exosuits at work. The study measured the productivity of workers equipped with exosuits, which can take up to 40% off a worker’s back every time they lift an object. Nearly all employees in the study experienced an increase in productivity, which improved by 8% overall, with workers reporting a 30% decrease in work-related discomfort.
Reducing the physical effort required for repetitive lifting tasks has enabled workers to remain active and efficient for extended periods of time, with a remarkable projected impact on ROI. This same company followed up more than 9 months later to report that no workers in the exosuit group had reported back injuries and that productivity improvements had been maintained, or even improved, for affected workers.
Improved security and increased productivity make wearable technology like exosuits an investment worth exploring for many businesses. The benefits of reduced workers’ compensation claims and productivity gains help businesses maintain efficiency in labor-intensive industries. Wearable technology creates a safer, more sustainable work environment in an industry where physical demands can make maintaining a stable, healthy workforce difficult.
Implementing Wearable Technology
Although exosuits offer obvious benefits, their successful integration into field worker operations depends on careful planning, particularly with regard to training and ability to derive maximum benefit. To successfully implement wearable technology, it is essential to provide ongoing support at various stages of the implementation process, including assessment and training on its appropriate use. Improper use or attempted use in tasks for which the suit offers no benefit may reduce efficiency or be a waste of worker time. Exosuits must also be properly fitted to each worker to maximize ergonomic support. Poorly fitted wearable technology can hinder movement and fail to provide adequate support, especially in physically demanding environments like food logistics, where restrictive conditions already pose problems. Equally important is ensuring that workers feel informed and understand the deeper “why” of using this technology. When everyone is aligned and sees the value, implementation becomes smoother and more meaningful for the entire team. Although simple and relatively brief, organizations should not overlook the importance of change management related to integrating this new technology into their workflows.
The long-term financial benefits can exceed the initial investment in security technology. Evaluating the expected ROI from implementing exosuits can often be positive and significant due to increases in productivity. In some cases, companies see an estimate ROI of 13 times and more over five years.
As businesses continue to face pressure to improve performance while reducing costs, the role of technologies such as exosuits is likely to expand, revolutionizing the way businesses approach worker safety. By reducing the risk of musculoskeletal injuries, exosuits can help create safer and more ergonomic workplaces, allowing workers to perform at their best without compromising their health. Exosuits offer an ergonomic solution to provide optimal comfort, efficiency and safety to workers, thereby enabling increased overall performance, superior results and a more satisfied workforce.