Optimizing Workstations to Reduce Overhead Reach
Ashley Mayo
Identifying Workplace Risks:
A worker sustained a shoulder injury while retrieving a 17 kg (37.5 lb) container from an overhead shelf, prompting an ergonomic assessment. The analysis revealed that excessive overhead reaching, high grip force demands, and extended horizontal reach distances placed undue strain on the shoulders, wrists, and upper back, increasing the likelihood of musculoskeletal injuries.
Ergonomic Redesign for Injury Prevention:
To mitigate these risks, a workstation redesign was implemented. The large shelving unit was replaced with a smaller unit, reducing overhead reach to 49 inches and horizontal reach from 28 inches to 3 inches. Additionally, top-shelf storage was limited to 10 kg (22 lb) containers, ensuring that all lifting remained within safe ergonomic thresholds. Task-specific training on proper material handling techniques was provided to sustain injury prevention efforts.
Measurable Safety & Efficiency Improvements:
Post-intervention assessments demonstrated a decrease in the Lifting Index (LI) from 10.0 to within safe ergonomic limits, significantly lowering shoulder and wrist strain. Workers reported improved accessibility, faster retrieval times, and reduced musculoskeletal discomfort, reinforcing the effectiveness of proactive ergonomic interventions.
