Ensuring the well-being of employees is not just about compliance — it’s about building a healthy, productive, and motivated workforce. One of the biggest workplace hazards that often goes unnoticed is poor ergonomics, especially for at-risk workers such as those with existing health conditions, older employees, pregnant workers, or staff performing repetitive tasks for long hours. In this guide, you’ll learn proven, easy-to-apply strategies to meet the ergonomic needs of these vulnerable groups and prevent injuries and discomfort on the job.
For organizations looking to improve their overall safety culture, professional training like the NEBOSH course in Pakistan provides an excellent foundation. This course covers various aspects of occupational safety and equips managers and safety officers with practical knowledge to identify and manage ergonomic risks effectively.
Why Ergonomics Matters for At-Risk Workers
At its core, ergonomics means designing a workspace that fits the worker instead of forcing the worker to fit the workspace. For employees who are more vulnerable — such as those recovering from injuries or dealing with chronic pain — poor ergonomics can quickly turn into serious musculoskeletal disorders (MSDs) and lost working days.
Let’s take Ali’s example: he worked at a small manufacturing unit and often had to lift heavy boxes. His employer didn’t provide proper lifting tools or training. Within a year, Ali developed severe back pain that not only affected his work but also his life at home. Simple changes could have saved him this pain and prevented costly downtime for the company.
Know Your Workers and Their Specific Needs
Before making improvements, employers must understand who is at higher risk. Common vulnerable groups include:
- Pregnant employees who may need adjustable seating or modified lifting duties
- Workers with chronic illnesses or physical disabilities
- Older workers who might have reduced flexibility or strength
- Staff exposed to repetitive movements or awkward postures daily
Carrying out a detailed assessment helps you spot which tasks pose risks and which areas need urgent attention.
Involve Workers in Finding Solutions
One of the smartest strategies is to involve employees in designing ergonomic solutions. After all, they know their daily struggles better than anyone else. Regular feedback sessions and safety meetings allow them to share ideas, report discomfort, and suggest practical changes.
Tip: Create an anonymous suggestion box or conduct short surveys. This makes it easier for shy workers to voice concerns.
Adjust Workstations and Tools
Simple changes can make a huge difference. Here’s how to modify workstations to fit workers' needs better:
Provide Adjustable Chairs and Desks
Everyone’s body is different. Adjustable furniture lets each employee fine-tune their chair height, back support, and desk level, reducing strain on the back, neck, and shoulders.
Organize Tools Within Easy Reach
Rearrange equipment so that workers don’t have to twist, bend, or overreach frequently. Use shelving, pull-out drawers, or adjustable stands to keep everything accessible.
Use Ergonomic Tools
Tools with cushioned grips and lightweight designs reduce the force needed and lower fatigue, especially for workers using hand tools all day.
Rotate Tasks to Avoid Repetition
Performing the same motion repeatedly is a leading cause of MSDs. Introducing job rotation breaks this cycle:
- Switch tasks every few hours
- Train workers in multiple roles to spread physical demands evenly
- Allow micro-breaks for stretching
A warehouse in Lahore reduced repetitive strain injuries by 35% just by rotating packers and loaders every two hours — a simple, cost-effective change.
Provide Proper Lifting Aids and Training
Manual handling is a big source of workplace injuries. Equip your team with trolleys, hoists, or conveyor belts where possible. Equally important is teaching them how to lift correctly:
- Keep loads close to the body
- Bend the knees, not the back
- Ask for help with awkward or heavy items
A NEBOSH safety course in Pakistan often includes manual handling training, helping workers master these life-saving techniques.
Focus on Lighting and Temperature
Ergonomics isn’t just about posture — environmental factors play a big role too:
- Ensure adequate lighting to reduce eye strain and awkward postures
- Maintain comfortable room temperatures; extreme heat or cold can lead to stiff muscles and fatigue
Encourage Movement and Stretching
Prolonged sitting or standing is dangerous. Encourage short, frequent breaks to stretch or walk around. Some companies even organize quick group stretches — a fun way to build team spirit and ease muscle tension.
Use Technology to Your Advantage
Modern tools like sit-stand desks, voice recognition software, and ergonomic keyboards make daily tasks easier and safer. For remote workers, providing guidance on setting up a home workspace is just as important.
Develop an Ergonomics Policy
For lasting results, integrate ergonomics into your health and safety policies. A written policy should cover:
- Roles and responsibilities for managers and workers
- Procedures for reporting discomfort
- Regular workplace assessments
- Training schedules for new hires and refreshers
Train, Monitor, and Improve Continuously
Ergonomic needs evolve over time. Regular refresher training, monitoring, and updates ensure your workplace adapts to changing tasks and technologies. Empower managers to spot risks early and address them immediately.
Final Thoughts
Meeting the ergonomic needs of at-risk workers isn’t just good practice — it’s a legal and moral responsibility. Simple adjustments, open communication, and regular training can prevent injuries and boost morale. When workers feel safe and valued, they’re happier and more productive.
Whether you run a small shop or a large factory, start small and build up. Listen to your people, make reasonable changes, and commit to continuous improvement. Your investment in ergonomics will pay off with healthier employees and a stronger bottom line.
