In production, “zero defects” is a frequent quality metric, but zero worker injuries, while a stated goal of most manufacturing plants and distribution centers, has not made it to the gold standard. There is no disputing that defective product costs companies millions of dollars in repairs, reshipments, and bad customer relations. Ironically though, cost containment through fewer workers’ compensation claims, litigation, absenteeism, and employer reputation has a more significant impact on the bottom line than all other quality initiatives combined.

All employers will agree in principle that workforce health and safety is paramount and affects quality. Yet the documented physical labor processes in most companies continue to reveal that that repetitive lifting, lowering, and moving injuries cost businesses millions of dollars each year. Automating those tasks significantly reduces the potential for injuries and downtime. No approach has been found for totally eliminating back injuries caused by lifting, though effective safety control programs and ergonomic design of work tasks can be greatly improved.

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