By Ashley Mayo, PT, DPT, AEP, Injury Prevention Specialist, Fit For Work
and Michael Hoonhorst, CPE, Senior Manager of Solutions Consultants, VelocityEHS
Adapted from the webinar “Ergonomics Evolved: AI, Insights, and the Future of Workforce Performance”
For decades, workplace ergonomics has been a critical, yet often reactive, component of workforce safety. Traditionally, ergonomic assessments relied on paper checklists, expert observation, and subjective judgment. But with the rise of artificial intelligence (AI), the field is undergoing a dramatic transformation. AI-driven ergonomic assessments are enabling organizations to move from a reactive approach—responding to injuries after they occur—to a proactive, data-driven strategy that prevents injuries before they happen.
What’s New: AI-Driven Ergonomic Assessments
AI is revolutionizing how musculoskeletal (MSK) risks are identified and managed. Rather than relying solely on human observation, AI-powered tools now use motion capture (often via smartphones or cameras) to analyze joint angles, posture, force, and frequency of movement. These tools assess risk factors in real time, delivering objective, repeatable results that reduce the subjectivity and variability of traditional assessments.
They also offer scalability: what once took days or weeks for a single ergonomist can now be accomplished in hours, with consistent accuracy across large facilities.
“With AI tools, you’re better able to standardize the assessments. It’s a simple, repeatable process, and that can help you get consistent results. You can go from doing two or three assessments in a day to over 10, if you have the right resources and process in place.” — Ashley Mayo
Real-World Impact: Case Studies and ROI
The shift to AI-driven ergonomics isn’t just about efficiency; it’s delivering measurable, real-world results:
- Large Facility Implementation: At a multi-acre industrial site, AI-based assessments helped quickly identify and address ergonomic risks. Simple, low-cost solutions—sometimes under $1,000—led to a 95% reduction in shoulder and lower back injuries over two years. Medical costs dropped at a similar rate.
- Manufacturing Assembly Example: AI analysis revealed that the primary driver of musculoskeletal risk was not workstation height, but the way parts were assembled. By training product engineers to consider ergonomics in design, the company reduced both injuries and costly quality issues, such as incomplete wiring harnesses.
These examples highlight that the ROI of AI-driven ergonomics goes beyond injury reduction. Improved productivity, higher quality, and greater employee engagement are all part of the value equation.
Refocusing Safety Teams on Solutions
One of the most powerful benefits of AI in ergonomics is that it frees up safety professionals to focus on what matters most: implementing solutions. Instead of spending hours collecting and analyzing data, teams can quickly identify high-risk activities before they result in injuries, collaborate with engineering and maintenance teams to implement improvements, and shift from measuring problems to proactively solving them.
“AI can take an overloaded and overburdened EHS team and handle much of the administrative work, allowing them to refocus their time and attention on improving the workplace, rather than just measuring existing issues.”— Michael Hoonhorst
Best Practices for Integrating AI
While AI brings speed and objectivity, successful integration depends on people. Engaging stakeholders early, from executives to frontline workers, is essential for building trust and buy-in. AI should be seen as a tool, not a replacement for professional judgment. Human experts are still needed to validate findings, interpret results, and ensure that solutions are practical and sustainable.
Training is also key. Empowering EHS teams and supervisors to understand and act on AI-generated insights ensures that data interpretation doesn’t remain solely in the hands of outside consultants.
Tips for Getting Started
Adopting AI into ergonomics can seem like a big shift, especially with concerns about data privacy, cost, and change management. Here are some tips to ease the transition:
- Start small: Pilot AI assessments in one area or department before scaling up.
- Address data privacy concerns: Work with IT and compliance teams to ensure data is handled securely. Many AI tools offer features like video blurring to protect sensitive information.
- Highlight quick wins: Share early successes—such as injury reductions or process improvements—to build momentum and stakeholder support.
- Focus on continuous improvement: Don’t let the pursuit of perfection stall progress. Even small steps toward proactive ergonomics can yield significant benefits over time.
Conclusion: Embrace the Future of Ergonomics
AI is democratizing ergonomics, making it accessible to more organizations and empowering frontline teams to take an active role in workplace safety. By embracing AI-driven assessments, companies can move from a reactive, injury-driven approach to a proactive, prevention-focused culture—protecting both their people and their bottom line.
Ready to take a proactive approach to workplace safety? Contact Fit For Work to learn how our innovative solutions can help you enhance productivity, reduce injuries, and achieve long-term success.
About the Authors
Ashley Mayo is an Injury Prevention Specialist at Fit For Work, providing services to clients in various industries. She holds a doctorate in physical therapy from Utica University and is an associate ergonomic professional (AEP). Since joining Fit For Work in 2022, Ashley has completed over 100 ergonomic assessments and developed tailored solutions for manufacturing, food distribution, and construction sectors. Passionate about understanding how the human body interacts with its environment, Ashley is dedicated to creating safer, more efficient workspaces through inclusive design and data-driven solutions.
Michael Hoonhorst is a Senior Manager and Ergonomics Engineer at VelocityEHS, overseeing the solutions consulting group to develop cost-effective solutions for organizations. Prior to joining VelocityEHS, Michael was a graduate assistant at Western Michigan University, teaching ergonomics and statistics, and performing ergonomics research for local companies such as Haworth, Stryker, and Bronson Hospital. Michael holds a Bachelor of Science in industrial engineering with a minor in mathematics, and a Master of Science in industrial engineering with a focus in occupational ergonomics, both from Western Michigan University. He is recognized as a certified professional ergonomist (CPE).
