MSD Prevention Technology: Turning Worker Feedback into Safer Workplaces

The National Safety Council (NSC)’s Musculoskeletal Disorder (MSD) Solutions Lab recently surveyed 405 frontline employees across various industries to better understand their experience with MSD prevention technology. Industries that provided feedback for this study included manufacturing, construction, healthcare, transportation, and warehousing, among others. This study specifically focused on non-managerial employees whose jobs typically involve manual labor and who had used at least one MSD prevention technology in their current position.

The report examined workers’ perceptions of several emerging technologies, including wearable sensors, computer vision, exoskeletons, robots, collaborative robots (cobots), digital twins, and extended reality (XR). These technologies may offer valuable opportunities to strengthen workplace safety and reduce the likelihood of MSDs as organizations seek more proactive approaches to identifying ergonomic risk factors.

“Emerging prevention technologies provide organizations with valuable capabilities to identify physical and psychosocial risk factors that may contribute to MSDs, including carpal tunnel syndrome, tendonitis, and back injuries, before incidents occur,” said Steve Simon, Senior Risk Control Manager at Safety National. “However, technology should be viewed as one component of a comprehensive prevention strategy. The most effective outcomes are achieved when these tools are integrated with robust ergonomic programs, active employee participation, and a disciplined risk management framework focused on continuous improvement and injury prevention.”

Moving From Reactive to Proactive

The survey found that 70% of frontline workers reported experiencing MSD symptoms, while 64% of those said symptoms had resulted in missed work. In response, employers are increasingly exploring emerging technologies designed to prevent MSDs.

Workers’ perceptions varied across the different types of MSD prevention technologies that were evaluated. Technologies that provided direct physical assistance, such as exoskeletons and robots or cobots, were viewed most favorably for their ability to reduce musculoskeletal discomfort and related symptoms. While computer vision systems and wearable sensors were less likely to be perceived as an effective method to directly alleviate symptoms, employees reported that nearly all technologies enhanced their awareness of physical stressors and ergonomic risk factors.

Notably, 90% of respondents agreed that exoskeletons, digital twins, and wearable sensors improved their understanding of MSD risk factors in the workplace. This highlights the broader value of emerging technologies, not only as intervention tools, but also as mechanisms for increasing employee awareness and supporting proactive injury prevention efforts. These results suggest that organizations should evaluate prevention technologies based not only on their intended functionality, but also on how employees experience and perceive the benefits of technology. Employee buy-in may play a significant role in the overall effectiveness and long-term success of technology-driven ergonomics initiatives.

The Value of Worker Involvement

The study found a strong relationship between worker involvement and the perceived effectiveness of MSD prevention technologies. Employees reported more favorable outcomes when they were actively engaged in the implementation process and had opportunities to provide input regarding the adoption and use of new technologies.

“The effectiveness of an MSD prevention technology may depend as much on employee acceptance and engagement as the technology itself,” Simon said. “When employees understand the purpose of a new tool and are given opportunities to provide feedback, they are more likely to support its adoption and use it as intended.”

Building Trust to Reduce Risk

Establishing trust between leadership and employees is important for successful technology implementation. Organizations should clearly communicate the purpose of new technologies, the safety and operational benefits they are intended to provide, and how they will be integrated into existing work processes. Comprehensive training, transparent communication, and ongoing opportunities for employee feedback can help foster confidence and encourage usage.

When employees view technology as a resource designed to enhance safety, reduce physical strain, and support job performance rather than as a means of monitoring individual activities, employee buy-in might improve. This collaborative approach can contribute to improved workforce engagement, reduced fatigue, enhanced productivity, and ultimately, a safer, more resilient workplace.