Musculoskeletal Disorders (MSDs) are among the most common causes of workplace ill health in the UK, affecting hundreds of thousands of workers each year. They can develop gradually from repetitive strain or poor posture, or they can occur suddenly when lifting something incorrectly.
Whether you manage a warehouse, run a construction site, or oversee office staff, MSDs are a risk that can’t be ignored. The good news? Technology and ergonomic innovation are offering powerful solutions to reduce this burden.
In this post, we’ll explore the top 5 work activities that contribute to MSDs, and how new equipment and modern methods can help your team work smarter and safer.
1. Manual handling of loads
The risk:
Lifting, lowering, pushing, pulling, or carrying loads manually continues to be one of the leading causes of back injuries and MSDs. Poor technique, excessive weight, and awkward postures increase the risk significantly.
How to avoid it:
- Eliminate the need to handle items manually where possible (e.g. redesign workflows).
- Use lifting aids such as electric pallet trucks, vacuum lifters, and scissor lift tables to reduce strain.
- Introduce collaborative robots (cobots) in manufacturing and logistics environments to automate repetitive lifting tasks.
- Provide manual handling training – but remember this is a last line of defence, not a substitute for safer systems.
2. Prolonged or poor seated postures
The risk:
Sitting for long periods, especially with poor posture or inadequate chair support, contributes to lower back pain, neck strain, and shoulder tension.
How to avoid it:
- Switch to adjustable sit-stand desks to encourage movement throughout the day.
- Invest in ergonomic seating that supports the lumbar spine and allows for dynamic movement.
- Use monitor arms and laptop risers to ensure screens are at eye level.
- Introduce posture-detecting wearable tech that prompts workers to adjust position or take breaks.
3. Repetitive work
The risk:
Repetition of the same movements, especially at high speed or with force, can lead to repetitive strain injuries (RSIs), especially in the wrists, hands, and shoulders.
How to avoid it:
- Redesign workstations to reduce reach and allow neutral postures.
- Automate high-frequency tasks using conveyors, robotic arms, or task-specific automation.
- Introduce job rotation to vary physical tasks and reduce fatigue.
- Use exoskeletons to support arm movement in overhead or front-facing tasks.
4. Working in Awkward or Static Postures
The risk:
Tasks that require kneeling, bending, reaching overhead, or twisting – especially when held for prolonged periods – place strain on muscles and joints.
How to avoid it:
- Redesign the task or workspace to bring work within comfortable reach.
- Use adjustable workbenches or mobile platforms to position work at the right height.
- Provide tools with extendable handles to reduce the need for stretching or bending.
- Adopt wearable motion sensors that identify poor posture trends and prompt early intervention.
5. Use of hand tools and vibrating equipment
The risk:
Sustained use of vibrating tools such as grinders, drills, and impact wrenches can cause Hand Arm Vibration Syndrome (HAVS) and other MSDs. Poorly designed tools may also increase grip force and awkward wrist positions.
How to avoid it:
- Choose anti-vibration tools and low-vibration variants that meet ISO standards.
- Use tool balancers and supports to reduce the effort required to handle heavy or awkward equipment.
- Adopt battery-powered tools with ergonomic grips to minimise weight and torque reaction.
- Monitor vibration exposure levels with wearable HAVS tracking systems to stay within safe limits.
Overall common themes in preventing MSDs
- Design tasks to fit the worker, rather than forcing the worker to adapt to poor design.
- Eliminate or reduce manual effort through automation, lifting aids, or better workflows.
- Encourage regular movement and task variation to avoid static or repetitive postures.
- Use ergonomic equipment and adjustable workstations to promote neutral, comfortable positions.
- Implement technology for early detection, such as wearable posture sensors or vibration exposure monitoring.
- Engage with employees to gather feedback and involve them in identifying risks and solutions.
- Foster a culture of prevention, where physical wellbeing is prioritised, not treated as an afterthought.
- Review and improve work processes regularly to adapt to changing demands and technologies.
The positive impact of technology on reducing MSDs
Technology is transforming the way we approach musculoskeletal health in the workplace. These advancements are helping to identify risks earlier, reduce the physical demands of tasks. Rather than relying solely on training or PPE, we’re now seeing a shift towards engineered and automated controls that tackle the root causes of MSDs. The result is not only fewer injuries and absences, but also a safer, more efficient, and more engaged workforce.
The Role of Wearable Technology in Managing Musculoskeletal Risk
Discover how wearable technology can help you manage musculoskeletal risk
