New research from ProGlove reveals that ergonomic debt is threatening operational productivity in warehouses across the UK and United States as physical strain, due to poor tools and rising demand, is getting worse.
In fact, the research shows that although ergonomic issues are escalating, most organizations are not fully aware of the risks or are addressing them effectively.
“The fact that 66% of warehouse managers have never heard the term ergonomic debt tells us that too many warehouse workers are carrying a physical burden that has gone unrecognized for far too long,” says Konstantin Brunnbauer, managing director at ProGlove. “When I speak with operators, they often describe strain as simply ‘part of the job.’ But there’s only so much strain a body can take, and it will only get worse as demand increases. This research shows how that burden is already influencing fatigue, absences, and whether people feel able to stay in these roles - those outcomes directly affect productivity.”
Key takeaways:
· Ergonomic debt is the cumulative strain that builds up from repetitive motions and heavy or outdated tools not designed with people in mind, ultimately leading to lower productivity, absenteeism, and higher staff turnover.
· More than 73% of warehouse operators say they have considered leaving their roles because of discomfort or injury concerns. As a result, 36% of workers say they missed shifts in the past year due to work-related pain or exhaustion.
· Among those who took time off due to fatigue, 50% missed between 4-6 days a year, while 15% missed between 1-2 weeks of a working year.
· 53% of workers still use pistol-grip scanners, which are known to elevate musculoskeletal risk, with 8% more workers than managers rating their tools as non-ergonomic, at 81% and 73%, respectively.
· Despite this, only 22% of organizations measure RSI or MSK injuries according to their warehouse operators. 73% of surveyed warehouse managers say the tools in their facility are not ergonomic, while 37% of managers say their workflows are not designed to prevent RSI or MSK injuries.
