Since October 2023, inspectors from the Occupational Safety and Health Administration (OSHA) have been conducting unscheduled visits to distribution centers (DCs) and warehouses as directed by its National Emphasis Program (NEP). Why these facilities specifically? The agency notes that warehousing and logistics employ more than 1.9 million — and have double the injury rates of other industries. Although OSHA does not have regulations surrounding ergonomics, the agency is including those practices as part of the NEP inspections. Therefore, to remain compliant and avoid hefty fines, it’s crucial to prioritize warehouse ergonomics in your operations.

What is OSHA’s Warehouse and DC NEP?

An OSHA NEP is a temporary program that focuses resources on hazards and high-hazard industries identified by the agency, based on data obtained from the Bureau of Labor Statistics. On July 13, 2023, OSHA issued Directive Number CPL-03-00-026. This directive identified warehousing and DC operations as having higher than normal injury rates.

During this three-year program, OSHA will conduct safety inspections targeting specific hazards. Focus areas include powered industrial vehicle operations, material handling and storage, walking and working surfaces, means of egress, and fire protection. In addition, OSHA will assess heat and ergonomic hazards. Should an OSHA inspector identify the presence of these hazards, the agency may conduct a health inspection.

“Prior to 2023, OSHA primarily investigated workplace accidents. But with the NEP the agency now has a mandate to investigate ergonomics,” noted Rob Jorden, Vice President of Engineering at Blickle Wheels & Casters USA. The company is a member of the Ergonomic Assist Systems & Equipment (EASE) Council.

Warehouse Ergonomics: How to Identify Areas for Improvement

Ergonomics studies how people interact with their environments. In a warehouse, it ensures that the design of the equipment, tasks, and workspaces minimizes physical strain and discomfort. By improving warehouse ergonomics, an operation can reduce the risk of injuries, improve employee morale, and enhance overall productivity.

Operations unsure which tasks are ideal for ergonomic improvement should listen to employees’ feedback, Jorden noted.

“If there’s a certain aspect of a job that workers complain about repeatedly, or that makes people sore, take a closer look. Or a task where people frequently get hurt — even if you rotate through positions. That is likely one that could benefit from better warehouse ergonomics,” he said.

Jorden pointed out that with the proper ergonomic equipment, employees can repeatedly lift or move heavier loads with minimal effort.

“Ergonomic equipment reduces fatigue associated with repetitive tasks, which therefore makes workers less prone to injuries,” he continued. “When workers are tired, that’s when accidents happen.”

Benefits of Ergonomic Improvements

Aside from avoiding fines from OSHA for poor ergonomic practices, an operation will experience other benefits from improving warehouse ergonomics. They include:

• Lower overall costs: Both direct and indirect costs associated with ergonomic injuries will decrease as safety improves.
• Reduced injuries: Lowering the risk of musculoskeletal disorders (MSDs) such as back pain, carpal tunnel syndrome, and tendinitis.
• Improved employee morale: Workers who feel comfortable and cared for by their employer are more likely to be satisfied with their jobs.
• Increased productivity: A more ergonomic workplace can lead to higher efficiency and reduced absenteeism.
• Enhanced company reputation: Demonstrating a commitment to employee safety and well-being can improve a company’s image.

Key Equipment for Better Ergonomics

EASE Council members often work together to help a facility implement the optimal ergonomic solutions that complement each other, Jorden added. The next post on this topic will explore a diverse range of ergonomic equipment that can help a warehouse and DC ensure OSHA ergonomic compliance. Solutions include:

• Height-adjustable workstations
• Industrial carts with smooth rolling wheels and casters
• Motorized material transfer solutions
• Overhead lift assist devices
• Lift tables
• Portable ergonomic conveyors
• Lighting
• Ergonomic storage

Find More OSHA Compliant Solutions for Warehouse Ergonomics

The EASE Council offers a broad range of complimentary educational resources on its website. These include case studies, videos, and seminars. Further, its members are available to consult, answer questions, and offer advice on ergonomic best practices and safe equipment use.