Rising Ergonomic Debt in Warehouses Threatens Operational Efficiency

[Ahmet Ö.]

New research has been published indicating that physical strain in warehouses, stemming from unmeasurable muscle fatigue due to old and inefficient equipment, is termed "ergonomic debt." This situation leads to a decrease in operational efficiency and an increase in employee turnover.

This research, conducted by ProGlove with over 200 warehouse workers and managers in the UK and US, reveals that with increasing demand, poorly designed tools exacerbate physical strain, and businesses, despite being aware of the risks, are not taking adequate precautions.

Ergonomic debt is defined as musculoskeletal problems arising from the accumulation of unsuitable tools and repetitive movements. This leads to productivity loss, absenteeism, and high staff turnover.

### Research Findings

• More than 73% of warehouse workers stated they considered leaving their jobs due to discomfort or concerns about injury.
• 36% of employees missed work last year due to work-related pain and fatigue.
• Among those who took leave due to fatigue, 50% were absent for 4-6 days a year, and 15% were absent for 1-2 weeks.
• 53% use pistol-grip barcode scanners, which increase the risk of musculoskeletal disorders.
• 81% of employees and 73% of managers believe the tools they use are not ergonomic.
• Only 22% measure repetitive strain and musculoskeletal injuries in the workplace.
• 73% of managers stated that equipment is not ergonomic, and 37% said workflows are not designed to prevent such injuries.

### Impact of Ergonomic Debt on the Workforce
Increased physical strain exacerbates the existing labor shortage; every absence and resignation increases costs and operational burden for businesses. Since most warehouses lack the data and language to identify the true causes of fatigue and turnover, they continue to operate with equipment and methods that worsen the problems.

Konstantin Brunnbauer, Managing Director at ProGlove, states, "The fact that 66% of warehouse managers have never heard of the concept of ergonomic debt shows the magnitude of the long-overlooked physical burden. Employees see strain as part of the job, but this situation will only worsen as demand increases."

Founded in 2014, ProGlove offers solutions that enhance efficiency, safety, and quality in the warehouse and logistics sectors through industrial wearable technologies. Headquartered in Munich, Germany, the company has offices in Chicago, Coventry, and Belgrade.

This research serves as an important warning regarding the sustainability of warehouse operations and worker health. It has become a critical necessity for businesses to take precautions against ergonomic risks with human-centered technologies.