5 Proven Strategies to Slash Workplace Injuries in Manufacturing and Distribution

Workplace injuries in manufacturing and distribution can be devastating, costing time, money, and morale. For EHS professionals, the ultimate goal is to keep employees safe while boosting productivity. Overexertion and strains are common in these fast-paced environments, but the good news? They’re preventable. Here are five proven strategies to reduce injuries, protect your team, and maintain smooth operations, utilizing solutions such as Functional Job Descriptions (FJDs), Post-Offer Employment Testing (POET), and onsite MSK clinics.

Understanding the physical demands of each role is step one. Lifting heavy pallets, operating machinery, or repetitive tasks in distribution centers can strain muscles and joints. Detailed Functional Job Descriptions (FJDs) outline exact requirements—weight lifted, frequency of motion, and posture changes. This clarity enables EHS teams to match tasks to worker capabilities, thereby reducing the risk of overexertion. Regularly review and update these descriptions at least every 2 years to reflect evolving roles and equipment in manufacturing and distribution settings.

Hiring the right fit for physically demanding jobs is critical. Post-Offer Employment Testing (POET) evaluates a candidate’s ability to handle tasks such as lifting, carrying, pushing, pulling, or standing—common in manufacturing and distribution. By ensuring new hires can safely perform their job duties, you prevent early injuries and establish a strong safety foundation. Tailor tests to specific roles, from forklift operators to assembly line workers, and watch injury rates drop while productivity climbs.

Musculoskeletal (MSK) injuries—such as strains, sprains, and back pain—are top concerns in manufacturing and distribution. In manufacturing, repetitive motions such as assembly line gripping or twisting to operate machines can often lead to carpal tunnel syndrome or tendonitis. In distribution, lifting heavy boxes or pallets can cause lower back strains, while prolonged standing for packing or sorting may trigger foot or knee pain. Onsite MSK clinics provide immediate care, identifying issues such as a sore shoulder or stiff back before they become serious. These clinics offer early intervention, body mechanics education, and self-care, helping to keep workers on the job and minimize downtime. A small 10x12-foot space can transform employee health, showing your team that safety matters.

Proper training saves backs and boosts confidence. Teach workers safe material handling techniques. Ergonomics assessments and interventions to address repetitive tasks, such as packing or assembly, also reduce strain. Address common MSK risks by teaching manufacturing workers proper tool-gripping techniques to prevent wrist strain and training distribution teams on safe lifting practices to prevent back injuries. Regular sessions for new and veteran employees reinforce habits, empowering EHS teams to lead a safety-first culture. Combine this with Functional Job Descriptions (FJDs) to align training with real job demands.

A strong safety culture ties it all together. Encourage open communication—let workers report early aches, like wrist pain from repetitive packing or back soreness from lifting, without fear. Utilize regular safety town halls to discuss ergonomics, lifting techniques, and hazard awareness tailored to the specific needs of manufacturing and distribution. Pair this with onsite MSK clinics for quick action and POET to start strong. Involve everyone—floor workers, supervisors, and EHS pros—to make safety a habit. Frequent breaks and stretching routines ease strain from standing or repetitive motions, keeping energy high and injuries low.

Why It Works
These strategies tackle the root causes of injuries in manufacturing and distribution: overexertion, poor fit, and lack of awareness. Common MSK injuries—lower back strains from lifting in distribution, carpal tunnel from repetitive manufacturing tasks, or knee pain from long hours standing—can be curbed. Functional Job Descriptions (FJDs) clarify demands, Post-Offer Employment Testing (POET) ensures readiness, and onsite MSK clinics catch issues quickly. Training and culture keep safety first, slashing lost time, medical costs, and turnover. The result? A safer, more productive workforce.

Take Action Today
EHS professionals, you’ve got this! Cut injuries and boost efficiency with these five steps. Explore WorkWell’s Functional Job Descriptions (FJDs), Post-Offer Employment Testing (POET), and onsite MSK clinics, to protect your team in manufacturing and distribution. Visit www.workwell.com to learn how we partner with you for a safer, stronger workplace!