Introduction
Proving the value of ergonomics requires data. This guide introduces six free ergonomic tools to help you build a strong business case for ergonomic improvements. Use them to:
- Identify ergonomic risks.
- Estimate the direct and indirect costs of injuries.
- Calculate the ROI for ergonomic investments.
- Design and visualize custom ergonomic solutions.
OSHA’s $afety Pays Estimator
What it is: The Safety Pays Estimator is a tool that helps employers understand the financial impact of workplace injuries and illnesses on their business. Average claim cost inputs are sourced from National Council on Compensation Insurance (NCCI). The tool outputs a report with direct/indirect costs and required sales to cover them.
How it works:
- Cost Calculation: The estimator uses a company’s profit margin, the average cost of an injury or illness, and an indirect cost multiplier to determine the total financial burden.
- User Input: Users can either select an injury type from a drop-down menu or manually enter the total workers’ compensation costs. They can also input their company’s specific profit margin and the number of injuries, although the tool provides default values.
- Result: The tool then calculates both the direct and indirect costs associated with the incident, ultimately showing the user the amount of sales needed to offset these expenses.
Link: https://www.osha.gov/safetypays/estimator
Pro Tip: Pair your results with an ergonomic evaluation so the dollar figures map to specific task risks you’ll fix.
ErgoDATA
What it is:
The ErgoDATA tool from the North Carolina State University Ergonomics Center is a suite of smart tools for conducting ergonomics screenings and evaluations of jobs. Its primary purpose is to help companies identify ergonomic stressors in the workplace and determine the risk of musculoskeletal disorders.
The tool works by providing a collection of specialized calculators and forms in a spreadsheet format, which users download to analyze specific tasks. These include:
- Industrial Screening Tool: Used to identify the level of ergonomic stressors by rating motion, force, and posture for different body parts.
- Calculators: A variety of calculators are available, such as the NIOSH Lifting Equation, the RULA Calculator, and the Strain Index, among others, to perform in-depth analyses.
How it works:
- Select the appropriate tool for the task being analyzed (e.g., lifting, pushing/pulling, or an office task).
- Download the corresponding Excel spreadsheet.
- Input data related to the task being performed. This could include weights, forces, postures, frequencies, and durations of actions.
- The spreadsheet then performs the calculations and provides a risk rating (e.g., Low, Moderate, or High) for the job or specific body parts.
- Based on the results, the practitioner can then decide if a deeper analysis is needed or if control measures should be implemented to reduce the risk.
This approach provides a structured way to systematically assess job tasks and make data-driven decisions to improve workplace safety and comfort.
Links: https://ergocenter.ncsu.edu/resources-and-tools-hub/ergodata/
Related Study: An Ergonomic Study was conducted by the Ergonomics Center of NC State University on the impact of ergonomics on productivity, lean, processes, and worker well-being. Download the white paper.
Liberty Mutual Workplace Safety Index (WSI)
What it is: The Liberty Mutual Workplace Safety Index is a study that helps businesses understand the most common and costly workplace injuries and illnesses. It’s not a real-time calculator like the other tools, but rather an annual report based on historical data.
How it works:
- Data Sources: The index is created by analyzing nonfatal injury data from the U.S. Bureau of Labor Statistics (BLS) along with Liberty Mutual’s own claims data.
- Cost Analysis: The study identifies events that caused employees to miss more than five days of work. It then ranks these incidents based on their workers’ compensation costs.
- Ranking and Insights: The costs are scaled to a total cost provided by the National Academy of Social Insurance (NASI) to create a comprehensive ranking of the most expensive types of injuries. The goal is to provide companies with actionable insights so they can focus their safety efforts on the biggest risks.
Link: https://business.libertymutual.com/workplace-safety-index/
The index uses data from three years prior to its publication year. For example, the 2025 Index would be based on data from 2022.
BOSTONtec Ergonomic ROI Calculator
What it is: The BOSTONtec ROI Calculator is an interactive tool to calculate the potential return on investment for ergonomic workstations. By showing quantifiable results, this tool can be used to transform ergonomic investment from a perceived cost to a strategic investment.
How it works: The user inputs specific data points related to their operation.
The calculator provides a report that includes dollars and hours saved per day and how long it takes to break even.
Link: https://www.bostontec.com/calculate-your-ergonomic-roi/
Pro Tip: This tool is based on the reduction in cycle time with ergonomic workstations according to the Ergonomic Study. Combine this ROI Calculator with OSHA’s Safety Pays Estimator to see an even more impressive ROI.
Related “How-to” Blog: How to Justify Workstation Upgrades to Upper Management
BOSTONtec 3D Workstation Builder
What it is: The BOSTONtec 3D Workstation Builder is an online tool that allows users to design and visualize their own ergonomic workstation in a 3D environment. It helps users create a workstation that is specifically tailored to their physical needs and the demands of the task, thereby promoting proper posture and reducing the risk of musculoskeletal injuries.
How it works:
- Select base frame, feet/casters, and work surface.
- Choose uprights.
- Add accessories and colors.
- Request a quote with drawing.
Link: https://www.bostontec.com/design-your-workstation/
Resources to help you build a better workstation:
PSHFES Ergonomics Cost-Benefit Calculator
The PSHFES Cost Calculator is a free, downloadable spreadsheet-based tool developed by the Puget Sound Chapter of Human Factors and Ergonomics Society (PSHFES). It is designed to help businesses justify investments in ergonomic interventions by estimating the potential financial benefits and payback periods.
The calculator works by using data from over 250 case studies of the outcomes of ergonomics programs. It allows users to:
- Input Specific Data: Enter information about a specific workplace problem, such as the number of employees affected, their hourly wage, and the types and frequency of injuries they have experienced over the past three years.
- Compare Options: The tool is structured to allow for a direct comparison of up to three different solutions or interventions, including a “do nothing” option.
- Calculate Costs and Benefits: It automatically calculates the direct and indirect costs of injuries, as well as potential savings from both injury reduction and productivity improvements. The calculations for indirect costs are based on ratios from OSHA’s “Safety Pays” Estimator.
- Generate Results: The output provides estimates of total annual savings and the payback period for each proposed solution.
The tool translates the abstract benefits of ergonomics into concrete financial terms, making it easier to make a business case to management.
Link: https://pshfes.org/cost-calculator
Conclusion
Explore these free resources to make data-driven decisions for a safer and more productive workplace. Need more guidance? Our team at BOSTONtec is here to help!
