The ROI of Workplace Ergonomic and Injury Prevention Programs

Extensive research and data shows the significant benefits of adopting proactive workplace safety and ergonomic programs. Studies reveal that such measures can yield substantial cost savings, increased productivity, and improved employee well-being. The data highlights how injury prevention and ergonomic programs can reduce workers’ compensation expenses by billions annually, while also decreasing disability periods, surgery rates, and other costly outcomes. Ultimately, the evidence demonstrates that investing in proactive workplace safety is not only the responsible choice, but also a smart financial decision for organizations.

Here are a few examples:

1. The Occupational Safety and Health Administration (OSHA) highlights that adopting injury prevention programs can yield substantial benefits, potentially saving employers between $9 billion to $23 billion annually in employee compensation costs. Additional OSHA studies indicate a significant cost to employers and employees when workplace health and safety policies are reactionary rather than proactive. OSHA estimates that implementing injury and illness prevention programs in the United States will reduce injuries by 15 to 35 percent for employers who do not currently have health and safety programs. At the 15 percent program effectiveness level, the estimated savings are $9 billion per year in employee compensation costs; at the 35 percent effectiveness level, the savings are estimated at $23 billion per year (OSHA, 2012).
2. The Workers’ Compensation Research Institute (WCRI) also underscores the advantages of early access to physical therapy for workers with lower back injuries, resulting in an 89% decrease in surgery usage, a 58% reduction in disability periods, and substantial cost savings across various aspects of the business. A study conducted by WCRI in September 2021 that analyzed the timing of physical therapy delivery to individuals with lower back injuries covered under workers’ compensation. The results indicated that early access to physical therapy was associated with:
   • 89% decrease in the use of surgery
   • 58% shorter total disability
   • 50% decrease in attorney involvement
   • 47% decreased use of MRI
   • 46% decrease in the likelihood of receiving an opioid prescription
   • 29% decreased use of injections
   • 24% reduction in claim costs
3. The top five most expensive employee claims total a staggering $33.5 billion, per a Liberty Mutual study in August 2023. These claims encompass lifting/overexertion ($12.8 billion), falls on the same level ($9 billion), falls to a lower level ($6.1 billion), other exertions or bodily reactions ($3.7 billion), and a slip or trip without a fall ($1.9 billion).Overexertion accounts for 21% of the top 10 injuries/illnesses, incurring direct costs of over $12.8 billion for employers and resulted in the most Days Away from Work, Job Restriction, or Transfer (DART) injury cases between 2021 and 2022. Overexertion injuries include:
   • Back injuries: Hurting one’s back is the most common overexertion injury. Back injuries can range from mild strains to severe spinal cord injuries. Some back injuries will require surgery, which can incapacitate the employee for quite some time. Many back injuries will require physical therapy.
   • Strains and sprains: Overexertion is overexerting force with a muscle strain or a ligament sprain. It’s a repetitive use injury. Boxes being lifted overhead, pulling or pushing crates, and carrying heavy items for long periods are some examples of overexertion injuries that can result in strains and sprains.
   • Joint injuries: Overexertion can lead to joint injuries, such as dislocations or fractures. These injuries can be caused by lifting, pushing, or pulling something too heavy for you.
   • Muscle tears: Overexertion can cause muscle tears, which can be painful and debilitating. This can happen by lifting, pushing, or pulling something too heavy for you.
   • Repetitive stress injuries: Overexertion and repetitive stress are the second leading cause of on-the-job injuries and accidents. Repetitive stress injuries can occur from performing the same motion repeatedly, such as typing or using a mouse. These injuries can lead to swelling, numbness, stiffness, chronic pain, or permanent loss of mobility in muscles, tendons, ligaments, and joints.
4. The total cost of work injuries in 2022 was $167.0 billion, according to the National Safety Council (NSC). This figure includes wage and productivity losses of $47.4 billion, medical expenses of $36.6 billion, and administrative expenses of $57.5 billion. This includes employers’ uninsured costs of $13.8 billion, including the value of time lost by workers other than those with disabling injuries directly or indirectly involved in injuries, and the cost of time required to investigate injuries, write up injury reports, etc. The cost per medically consulted injury in 2022 was $40,000, while the cost per fatality was $1,390,000. These figures include estimates of wage losses, medical expenses, administrative expenses, and employer costs but exclude property damage costs except for motor vehicles.

Achieving Workplace Safety Improvements and ROI with AI-Powered Ergonomic Software

The research underscores the compelling case for adopting proactive safety measures like Benchmark Gensuite’s Ergonomic Assessment AI-powered solution and 3motionAI’s 3DNeuroNet to illuminate ergonomic risks, modernize workplace safety, reduce costs, prevent injuries, and improve the overall well-being of employees. It emphasizes that businesses prioritizing safety protect their workforce and enjoy significant financial advantages.

• Proactive Workplace Safety/ROI on Safety Investment: Together, Benchmark Gensuite and 3motionAI’s ergonomic assessment software offer a proactive approach to workplace safety, enabling businesses to shift from reactive practices. The data highlights that investing in employee health and safety provides a substantial return on investment. Different industries, such as manufacturing, construction, and transportation, can expect varying levels of return, but all benefit from proactive safety measures.
• Financial Benefits of Safety Investment: By investing in injury prevention programs, employers can save between $9 to $23 billion annually in employee compensation costs, according to OSHA. The study suggests that for every dollar spent on employee health and safety, employers can expect an average return of 57.3%, emphasizing the financial gains associated with proactive safety measures. Early access to physical therapy, as highlighted by the Workers’ Compensation Research Institute (WCRI), results in substantial cost savings, including an 89% reduction in surgery usage, a 58% decrease in disability periods, and reduced costs across various aspects of operations.
• Objective Safety Metrics: Ergonomic software capabilities extend beyond traditional safety metrics by providing objective measurements of critical factors like biomechanics, posture, repetition, and manual material handling.
• Focus on Overexertion Injuries: Overexertion injuries, including back injuries, strains, sprains, joint injuries, muscle tears, and repetitive stress injuries, are a significant concern, accounting for 21% of the top 10 workplace injuries and costing employers over $12.8 billion in direct expenses.
• Long-Term Health Implications: Overexertion injuries can affect an individual’s health and well-being, leading to chronic pain, musculoskeletal disorders, reduced mobility, increased risk of future injuries, lost wages, and a diminished quality of life. Preventing these injuries is essential for both employees and employers.

With the help of Benchmark Gensuite and 3motionAI’s ergonomic assessments technology, organizations can better:

1. Identify risk factors: Identify the tasks that require heavy lifting, repetitive motion, or awkward postures. These tasks can increase the risk of overexertion injuries. Once you identify these tasks, you can develop strategies to reduce the risk of injury, such as using mechanical aids or changing the work process.
2. Conduct ergonomic assessments: Ergonomic assessments can help identify ergonomic risk factors and provide recommendations for reducing the risk of injury. A trained professional can conduct these assessments or use self-assessment tools.
3. Analyze work processes: Analyzing work processes can help identify areas where overexertion injuries are likely to occur. This can help you develop strategies to reduce the risk of injury, such as redesigning workstations or changing the work process.

To learn more about how these solutions can help your organization to reduce ergonomic injuries and costs, increase productivity, and improve employee well-being, contact us today.