"Most companies don't know which activity (in their plant or warehouse) has the greatest ergonomic risk," says Scott Smith, VP and ergonomics engineer at Humantech. As a result, most ergonomics programs are reactions to past injuries, rather than preventions of future ones.

"Traditional ergonomic programs are like running uphill through jello pushing a rope," says Smith. "Proactive ergonomics is like running downhill pulling a rope." Smith made his comments at a recent meeting of the Ergonomic Assist Systems and Equipment Council of the Material Handling Industry of America.

To be proactive, Smith says, managers first need to measure the risk of various materials handling activities. Then they need to determine the acceptable level of risk, and change those activities that don't meet it.

And while ergonomics is all about making the workplace easier to use day after day, Smith says that is not enough. Other measures of success include cost reduction, productivity improvement, reliability, impact on cycle times, and materials flow, as well as ease of integration with other activities. The most successful ergonomics programs, says Smith, are those that are sustainable and set a new standard.