Logistics sector : the MSD way

It’s hard to overlook such a statistic. 95% of recognized professional diseases in the transportation and logistics sector are related to musculoskeletal disorders (MSDs). Moreover, workplace accidents are very common: they are twice as frequent as in other sectors. 

And we see it clearly with our clients: the specificities related to the logistics sector are generally exacerbating factors to the occupational risks they face. From the back to the feet: the entire bodies of operators are subject to overuse. 

That’s why we want to take a step back and take stock. What lies behind these numbers? Why is the logistics sector severely affected by MSDs? And what can be implemented to limit the risks? 

Let’s explore this together. 

The logistics sector in France 

When we talk about logistics, we’re referring to the management of flows. The objective is simple: to ensure that the right product reaches the right recipient. And that too, within the shortest possible time. That’s why all operations involving warehousing, handling, coordination, transportation, and stock management converge towards this same goal. 

From an economic standpoint, it’s noteworthy that the logistics sector’s weight in France is considerable. Globally, we rank sixth in the market. And in Europe, we’re on the verge of clinching the silver medal: we’re in second place. 

In concrete terms? The logistics sector accounts for 2 million jobs. And a hundred different professions, such as : 

• Forklift operator ; 
• Truck driver ; 
• Order picker ; 
• Handler ; 
• Logistics technician ; 
• And inventory manager.  

The occupational risks of the logistics sector 

Now, let’s look at the professional risks associated with the logistics sector. And unsurprisingly, we’ll talk about manual handling. 

It’s a fact. In logistics and transportation, manual handling represents a significant portion of the workload. 

This greatly impacts the risk of MSDs for the numerous operators in this sector: handling loads is one of the leading causes of workplace accidents in the sector. And 70% of sick leave is related to back pain. 

How can we explain this? Repetitive manual handling operations (boxes, pallets, bins, suitcases, etc.) can bring a host of risks. 

Take the example of the order picker profession, particularly exposed to MSD risks. This profession requires many physical efforts due to the movement of loads of varying weights and repetitive gestures. These demanding tasks can lead to muscle contractions that may result in muscular pathologies for operators… Disabling pains that can even lead to a complete inability to work.

The risk factors of manual handling exposing employees to MSDs include: 

• The weight of the load lifted ;  
• The distance traveled with the load ; 
• The duration of the movement ; 
• As well as the number and frequency of lifting movements performed. 

Beyond load handling, the operation of handling equipment is also a risky task for employees. 

Although self-propelled trucks and pallet jacks are designed to reduce biomechanical constraints and increase performance and productivity… They have also brought their share of occupational risks, such as: 

• Overturning ; 
• Crushing or collision ; 
• Noise ; 
• Increased vigilance, etc. 

It should also be noted that exposure to permanent vibrations can generate numerous risk factors for musculoskeletal disorders in operators. And they can lead to injuries in the hand, wrist, elbow, shoulder, or even the back and neck. 

And the consequences can be very impactful for operators. We’re talking about pain, but also reduced manual strength or impaired sensitivity or dexterity. Operators can also develop Raynaud’s syndrome, or early arthritis. 

The example of a Moovency customer specializing in logistics  

Let’s get more specific and support our statements with an example straight from one of our clients, a specialist in the logistics sector. The company contacted us to conduct an ergonomic assessment.

We had two objectives: 

• Prevent the onset of MSDs by improving the working conditions of employees. 
• Improve the performance indicators of the company, particularly by reducing “breakage” and the risk of workplace accidents. 

To achieve this, we conducted a thorough analysis, accompanied by our tool KIMEA, the solution for quantifying the biomechanical risks of MSDs. By using biomechanical factors as our starting point and armed with reliable numerical data, we were able to precisely examine other risk factors: organizational, individual, environmental, and psychosocial. 

Here’s how our intervention unfolded with our client : 

• Steering Committee (COPIL) kickoff
• Observation of the company 
• Preparation 
• Container unloading 
• Picking 
• Loading
• Working group
• Presentation of results 
• Co-construction of solutions 
• Interview with management and discussion of options
• Oral feedback to the COPIL
• Monitoring the deployment of solutions for 1 year 

For our example, let’s focus on the operation of loading and unloading containers, operations that our KIMEA solution identified as being the most at risk. 

Our analysis identified several factors that could influence the activity and its impact on the operators’ health. Here are some examples : 

Other factors influencing loading and unloading operations 

During our analysis, we noted several factors that could influence operations. Among others, we detected: 

•  The unpredictability of container arrivals ; 
• Unloading related to the “guard” price of the container at the dock ; 
• The arrival of several containers on the same day or from multiple suppliers ; 
• And the quantitative and qualitative verification of products during unloading using paper and pencils, leading to a risk of error and difficulty in recourse if there is a delivery mistake. 

Objectives and constraints related to organization 

During their tasks, operators must try to find ways to facilitate container (un)loading. 

Their objective is to organize the tour as efficiently as possible, as they must fill the truck as much as they can. Thus, they must find a way to fit everything in while also grouping the load to facilitate unloading. 

The layout in the preparation area, the equipment provided, and feedback from the after-sales service are all factors that contribute to the variability of their work environment. 

But as we’ve seen, the operators at our client are also facing time pressures. These are particularly caused by the arrival of several containers at the dock on the same day. This pushes the operator to redouble their efforts to ensure the smooth handling of arrivals. 

Implementing an MSD prevention approach : what are the benefits ? 

Reduction of absenteeism 

Certainly, the health crisis has caused numerous absences… But even before 2019, the results showed a clear increase in absenteeism in companies. 

Fighting against MSDs means fighting against absenteeism within your organization. And this will allow companies to… 

• Secure their production capacity ; 
• Retain their team ; 
• Retain their customers ; 
• But it also saves time and money, while maintaining control over the entire production process. 

A boost for attractiveness 

Because a company where it is known that the employer cares about our health… is a company that will attract future candidates. 

Today, social networks reveal the backstage of companies to everyone: the measures taken to protect employees, managerial practices, etc. And, in the digital world, the image perceived by the public can make a difference. That’s why it can be a real attractiveness lever.

Reduction of direct and indirect costs related to MSDs 

Well-known and often dreaded by companies, the financial burden of workplace accidents (WA) and occupational diseases (OD) contributions is a direct cost that should not be overlooked. 

The rate of this contribution, borne by the employer, varies depending on the number of workplace accidents reported each year. And the financial impact of logistics is significant: 73 million euros in contributions are paid by companies in the sector. 

Indirect costs, on the other hand, can amount to up to 2,500 euros per year, per employee. They include, among others: 

• Increase in absenteeism ; 
• Decrease in productivity ; 
• Activity restrictions ; 
• Or the training of replacements. 

Did you know? Financial aid is available to help you implement your prevention measures!

How to fight MSDs ? 

To prevent MSDs, companies must make work less strenuous for operators, without compromising their performance. And for that, solutions exist.
 

Evaluate risky postures through biomechanical analyses 

To effectively combat musculoskeletal disorders, we strongly advise companies to map out their positions. By equipping themselves with a thorough analysis, with reliable and quantified data, prevention specialists will easily identify which positions in their company are the most demanding and at risk. 

It will be easier to know where to start. And, as a result, which actions to prioritize. 

Prioritize your company’s prevention actions through the quantification of MSD biomechanical risks.

To be more concrete, let’s take the example of an order picker. The handling action remains relatively significant. 

The operator will have to pick items from a stock with different supply points to build their pallet. Depending on the stock, they may have to reach either high or low, and the muscular and articular impact will vary depending on the height. 

For example, when picking up a package from under the rack, there is a significant requirement for trunk flexion, which exposes them to strong articular constraints… and thus a potential risk of triggering MSDs. 

All of this will be visible through KIMEA. By capturing the operator’s movements via depth camera and connected gloves or the KIMEA App, all articular constraints will then be evaluated and presented through a very understandable score for prevention specialists (RULA, REBA, or KIMEA). 

This quantification of biomechanical risks can also help companies comply with standards related to manual handling, which is inherent to common operations in the logistics sector. 

Despite its significant role in the French economy, the logistics sector unfortunately isn’t spared from musculoskeletal disorders (TMS). 

The causes ? Handling loads and repetitive movements. But not only that. Organizational and psychosocial factors also contribute their share of aggravating risk factors for all operators. 

Moovency positions itself as a partner to companies in terms of health and prevention. We support companies in framing and implementing their actions using our tools and guidance. Our mission is to help companies take ownership of their prevention approach within their structure and the actions to be taken with their employees. 

So, don’t hesitate any longer. Invest in preventing the risks of MSD.