Musculoskeletal disorders (MSDs) remain a significant challenge in workplace safety, with the private sector 976,090 musculoskeletal disorder cases that led to days off of work in 2021-2022. These injuries, often caused by repetitive motion, force, vibration, and awkward positions, can result in severe sprains, strains, and back injuries.

According to and the , workers in warehouse and distribution roles also face some of the highest rates of serious injury, particularly from overexertion. Reducing these risks not only protects physical health, but also contributes to stronger retention and overall employee well-being.

Innovative Risk Management Solutions

Amerisure’s commitment to pioneering innovative safety solutions has recently seen remarkable advancements under the . With a focus on cutting-edge technology to combat workplace injuries, Amerisure was awarded a safety grant to pilot , designed to mitigate lower back injuries—a prevalent concern in MSD-related claims.

“Amerisure is proud to support the NSC’s efforts to develop repeatable, real-world safety solutions,” said Ryan Anderson, Risk Management Technology Programs Manager at Amerisure.

“We see firsthand how physically demanding jobs take a toll on workers. That’s why we’re so focused on prevention—especially through emerging technologies that help our �鶹ԭ�� protect their teams.”

Real Results

Amerisure partnered with several �鶹ԭ�� across various regions to evaluate the impact of HeroWear exosuits in real-world work environments. Two organizations participated in a 90-day pilot program, while another conducted an extended 12-month evaluation.

During this time, employees integrated these cutting-edge exosuits into their daily routines; extensive feedback was collected through employee surveys, alongside critical HR metrics like injury rates, productivity levels, absenteeism, and turnover rates. This comprehensive data collection allowed the study to capture both the quantitative and qualitative benefits of the exosuit technology in real-world applications.

The results were compelling:

• One company reported a 40.74% decrease in worker fatigue from heavy lifting and a 26.92% reduction in lower back discomfort
• Another detailed a 42.19% reduction in fatigue from heavy lifts alongside a 32.84% reduction in lower back discomfort
• Among nearly 100 workers using exosuits for over a year, zero back strain injuries were reported, along with an average 42% reduction in lower back discomfort and a 26% drop in work-related fatigue

“At Amerisure, my goal in working with each of my clients is to mitigate any potential risks to their business—which includes protecting each of their workers,” said Anderson. “It’s exciting to see measurable results in the data—but even more meaningful to witness firsthand how this technology is improving safety, comfort, and confidence on the job.”

Promising Results and Future Plans

Following a successful showcase at the National Safety Council’s Annual Congress and Expo last fall, plans are underway to expand the use of the HeroWear exosuits across more �鶹ԭ��—bringing this proven safety innovation to more workplaces where it can have a meaningful impact.

“We are thrilled to be identified among the nation’s top safety innovators and work together with the NSC in implementing cutting-edge solutions for the prevention of workplace injuries,” said Kevin Clary, Vice President of Risk Management at Amerisure. “Our participation in the grant program reflects a core part of our service philosophy—delivering emerging safety technologies that help our agency partners and �鶹ԭ�� create safer, more resilient workplaces.”

For more updates and to explore how we’re working together to make safety a priority, visit amerisure.com

Forklifts are vital for operations in warehouses and job sites, but they also carry inherent risks that require vigilant management. The underscores the importance of forklift safety, listing powered industrial trucks among its . These citations often arise from avoidable incidents such as collisions and tip-overs, which can have catastrophic consequences.

Mandatory Seatbelt Usage

One of the non-negotiable rules set by OSHA is the mandatory use of seat belts by forklift operators. Non-compliance not only leads to substantial fines but also increases the risk of fatal accidents. In fact, OSHA statistics indicate that due to equipment tip-overs, with machines often weighing over 9,000 lbs. The simple act of buckling up can be lifesaving.

Training, Certification, and Cleanliness

A thorough review of the organization’s safety manual should be a priority during any inspection. It is crucial to ensure that all forklift operators are properly trained and certified. Equally important is the cleanliness and orderliness of the operating environment. Floors should be clear of debris that could obstruct pedals or cause operators to trip, and the cabs should not be used for storing unrelated materials as outlined in .

Routine Inspections and Hazard Analysis

OSHA mandates daily or pre-shift inspections of all powered industrial trucks to maintain safety standards. This regular check, as detailed in is designed to assess the operational readiness of equipment, ensuring that everything from brakes to warning labels is in optimal condition. Additionally, conducting Job Hazard Analyses (JHAs) is essential for identifying and mitigating risks associated with forklift operations.

Best Practices for Safe Operation

Adhering to best practices is key to ensuring safety. Operators should always:

• Drive in reverse only when necessary and safe.
• Keep both hands and shoes dry to prevent loss of control.
• Follow all designated traffic and safety signage.
• Ensure the forklift is turned off and secured when not in use.
• Always wear a seatbelt and conduct a safety check before movement.

Looking Ahead

Creating a culture of safety goes beyond compliance—it involves education, awareness, and continuous improvement. For more resources on risk management and safe equipment operation, visit our Risk Management page. Empower your team with the necessary tools and knowledge to operate safely and efficiently every day.

Mandatory Seatbelt Usage

One of the non-negotiable rules set by OSHA is the mandatory use of seat belts by forklift operators. Non-compliance not only leads to substantial fines but also increases the risk of fatal accidents. In fact, OSHA statistics indicate that due to equipment tip-overs. With machines often weighing over 9,000 lbs, the simple act of buckling up can be lifesaving for operators.

Training, Certification, and Cleanliness

A thorough review of the organization’s safety manual should be a priority during any inspection. It is crucial to ensure that all forklift operators are properly trained and certified. Equally important is the cleanliness and orderliness of the operating environment. Floors should be clear of debris that could obstruct pedals or cause operators to trip, and the cabs should not be used for storing unrelated materials as outlined in .

Routine Inspections and Hazard Analysis

OSHA mandates daily or pre-shift inspections of all powered industrial trucks to maintain safety standards. This regular check, as detailed in is designed to assess the operational readiness of equipment, ensuring that everything from brakes to warning labels is in optimal condition. Additionally, conducting Job Hazard Analyses (JHAs) is essential for identifying and mitigating risks associated with forklift operations.

Best Practices for Safe Operation

Adhering to best practices is key to ensuring safety. Operators should always:

• Drive in reverse only when necessary and safe.
• Keep both hands and shoes dry to prevent loss of control.
• Follow all designated traffic and safety signage.
• Ensure the forklift is turned off and secured when not in use.
• Always wear a seatbelt and conduct a safety check before movement.
• These operational guidelines are crucial for maintaining a safe working environment and are supported by OSHA’s comprehensive safety training programs.

Looking Ahead

Creating a culture of safety goes beyond compliance—it involves education, awareness, and continuous improvement. Empower your team with the necessary tools and knowledge to operate safely and efficiently every day. For more resources on risk management and safe equipment operation, visit our Risk Management page or contact Amerisure Risk Management at riskmanagement@amerisure.com.

Manufacturers account for nearly of the U.S. economy’s total output, and the industry employs 8.4% of the workforce. Manufacturing remains among the top five largest employment sectors and is key to U.S. contributions, according to the United States Census Bureau. In fact, manufacturing generates approximately .

Roles within the sector are evolving as the industry landscape shifts, and the demand for highly skilled workers is rising across industries. Among the most in-demand manufacturing roles are those with a heightened digital skillset, focused in areas such as artificial intelligence and automation. In the next 10 years, four million roles will need to be filled in the sector. If left unfilled, missing manufacturing jobs could cost up to $1 trillion in 2030 alone, according to .

Leveraging Today’s Insights at Women in Manufacturing

Amerisure’s experts recently engaged with industry leaders and learned more about today’s insights and takeaways by participating as exhibitors during the annual Women in Manufacturing (WiM) Summit.

“It was inspiring to exhibit and support the WiM’s largest conference to date — with 1,700 participants from 324 companies, 42 states and 16 countries — and showcase how Amerisure supports manufacturing through our expertise and service capabilities with our in-person and virtual booths,” said Cindy Slubowski, Amerisure’s Manufacturing, Wholesale and Distribution Market Segment Leader.

In addition to the exhibit booth, Amerisure sponsored the summit’s “First Timers” reception and a 5K run for the Women in Manufacturing Educational Foundation, and company representatives attended the conference’s educational workshops and presentations.

“There were many inspiring and thought-provoking sessions, such as 21^st Century Rosies presented by Boeing — the home of the original Rosie —and hearing from trailblazing women who ‘can do it’, and who have found their place to succeed in a male-dominated field,” said Slubowski.

The group learned about the “4.0 manufacturing modernization journey,” an industry concept led by engineers and operations employees to address robotics, automation, virtual models designed to reflect a physical object (also known as digital twins), and digitization in legacy and new manufacturing plants. There were also informative sessions on emotional leadership and steering high-performing teams. 

“The session on globalization was especially fascinating as reshoring and nearshoring are realities we are starting to see and can expect manufacturing to increase in the U.S. and Mexico in the next few years,” said Slubowski.

Protection Forged in Partnership

Amerisure is investing in our products and our people to help protect manufacturing businesses. Learn more about the unique coverage and safety technologies to complement your manufacturing programs, including new products and industry-leading service for more manufacturing businesses.

Common Hazards
Sometimes knowing the common causes and hazards of injuries can help prevent them. Lifting and bending injuries can be caused by:
 

• Overweight objects – Any object over 50 pounds, such as large spools of wire, bundles of conduit, or heavy tools, can cause serious stress to the ligaments, muscles, and joints of your shoulders and back.  
• Awkward positions – Bending, twisting and reaching while lifting forces the back to support both the body and load’s weight, overexerting your muscles. Also, carrying loads on one shoulder, under one arm, or with one hand can create unsafe pressure on the spine. The risk for awkward posturing increases when loads have inadequate handholds.
• High frequency or long duration lifting – Supporting material for an extended period of time, such as when installing wiring, can increase risk for back or shoulder injury by denying muscles nutrients, allowing for the buildup of waste products and causing fatigue.
• Environmental concerns – Extreme temperatures can decrease muscle flexibility, or lead to dehydration and fatigue. Also, poor housekeeping or low visibility in warehouses can lead to slips and falls.

Potential Solutions

You can help save your workers from these injuries by using smart lifting practices and implementing strength testing. You may want to consider implementing the following solutions at your workplace:
 

• Lighten the load – Reduce load weight by breaking them down into smaller quantities. When possible, use mechanical means, such as forklifts or duct lifts to carry loads too heavy to be carried by hand. Also, make use of ramps and lift gates when possible.
• Smart moves – Avoid awkward moves by using smart lifting practices. Begin by moving items close to your body, and bend your knees so the object is at mid-thigh or mid-chest height. Then, be sure to lift with your legs, not your back. When you need to turn, do so with your feet. Always avoid twisting your torso. If an object does not have adequate handholds, use the proper personal protective equipment, like gloves, to avoid unnecessary strain on the hands or use suction devices. Ask your supplier to place materials in containers with handholds.
• Beat fatigue – When installing wiring or doing other high frequency and long duration lifting, take frequent breaks or rotate often with other employees. Also, use stands, jigs, mechanical lifting and pre-assemble fixtures or boxes as much as possible before installation.
• Plan ahead – Keep your worksite safe by adjusting work schedules to avoid extreme temperatures and require your employees to wear the proper protective equipment. Also, be sure to provide proper lighting and keep the site organized and free from spills and debris.

Strength Testing

You also can prevent bending and lifting injuries in your workplace through strength testing your employees. Strength testing has shown to decrease almost one-third of all work-related injuries. You can determine which employees should be completing which lifts, as well as discourage unsafe lifting practices.

You might also want to consider implementing stretching or physical conditioning programs at the workplace. This can help workers be more prepared to lift heavy loads and prevent overexertion injuries. You are responsible for training all of your employees to lift safely using proper lifting techniques.

To learn more about how to protect your workers from lifting and bending injuries, contact your Amerisure Loss Control Consultant at (800) 257-1900 or losscontrol@amerisure.com.    

In fact, ergonomics should be a priority for all companies and their staff members. It doesn’t matter if the day is spent sitting at a computer, working in a warehouse or helping patients in a hospital – each job presents its own set of risks that can directly hamper a person’s ability to be productive. Recently, more employees and their companies are looking for ways to improve ergonomics in the workplace, and a report from the National Institute for Occupational Safety and Health may help shed some light on potential safety measures.

Posture can be a problem for workers
While many employers are focused on the big hazards on the job, there are other, smaller problems that can really add up to create additional workers’ compensation insurance claims and rising costs. One of those issues is posture, and every industry has to deal with this potential risk.

To address this topic, NIOSH partnered with the Canadian Centre of Research Expertise for the Prevention of Musculoskeletal Disorders to create a report that covers .

“Overexertion injuries to muscles, bones or joints cost U.S. businesses billions of dollars each year,” said Brian Lowe, Ph.D., research industrial engineer and NIOSH author. “This report can assist practitioners by providing research-based and practical recommendations to improve their practice of posture analysis of workers who are at risk of injury from lifting, pushing, pulling, carrying, or manual handling.”

In the report, NIOSH outlined several tips that could help employers determine if posture is a problem in their companies:

• Record employees at work from different angles
• Stress the importance of proper clothing for each task, especially during the assessment phase
• Focus on specific limbs that may be at risk of injury

Overall, NIOSH explained that a research-based approach to injury assessment can provide clear results and detail methods to improve safety and mitigate risk.

Employers look for ways to improve posture
While figuring out if a problem exists in the workplace is important, many employers are taking steps to improve safety one way or the other. For instance, a focus on ergonomics is starting to gain momentum across the country.

According to a community partnership website between the Kansas-based Lawrence Journal-World and the Lawrence Memorial Hospital, employees are starting to find ways to improve their posture on the job. In one office, several people have decided to use standing desks to avoid sitting for hours on end.

Kim King, a physical therapist at Lawrence Memorial Hospital, explained to the news source that addressing issues with ergonomics can prevent disorders such as carpal tunnel, tendonitis and tennis elbow. However, each employer must look at their own situation because there is rarely a common solution that works for everybody.

“We’re not a one-size-fits-all society,” she told the news source. “Some chairs fit smaller people better; some fit taller people. We shouldn’t order a chair just because it’s a good price; we should order it because it’s the right chair.”

Most importantly, employers should talk to their employees. It can help to have a meeting to discuss ergonomics and outline problems and solutions. This will be a good preventative first step toward limiting insurance claims and stopping injuries on the job.