Industrial Ergonomic Assessment
Industrial Ergonomic Assessment & Consulting Services
Production runs on people who must have the correct tools, and training to work in a healthy, productive fashion.
Pacific Ergonomics builds practical, sustainable safety solutions with you across diverse, high-demand industries including heavy manufacturing, warehousing and distribution centers, progressive assembly lines, high-speed packing and fulfillment zones, food and beverage processing, automotive and aerospace assembly, and medical device manufacturing.
We identify engineering, operational, and administrative bottlenecks at their source, turning physical stress factors into measurable improvements in line velocity, reduced injury rates, and sustainable shift performance.
Why Choose us
Certified Expertise. Engineering Backgrounds. Floor-First Focus.
Credentials Backed by Real-World Action
Our team holds the industry’s highest credentials, including Certified Professional Ergonomists (CPE) and Certified Industrial Ergonomists (CIE) and many are also Industrial Engineers. But we don’t lead with textbook theories. We lead with the practical mechanics of a live shift.
25 Years in True Industrial Environments
We leverage the top talent in the industry. Experience certified experts come from deep Industrial Engineering backgrounds. We’ve spent two and a half decades on plant floors, not in a classroom. We know equipment constraints, line speeds, and facility layouts. We design every fix to work under real operating conditions, not on paper.
We Find the Real Fix
A lot of ergonomic assessments end with a report full of risk ratings and no clear path forward. Ours starts there and keeps going. We work directly alongside your engineering, operations, and safety teams to turn findings into changes you can actually make, from a five-minute workstation adjustment to a fully engineered redesign.
A Plan Sized to the Problem
Not every risk requires a massive capital project or costly engineering changes. We work across the full spectrum—from a simple administrative adjustment made this week to an engineered redesign planned over a quarter—sizing the fix to match the actual risk profile and your budget.
Common Industrial Ergonomic Challenges We Solve
Manufacturing, warehousing, and industrial environments present unique ergonomic challenges where force, repetition, and production speed constantly compete against safety. Over time, that trade-off shows up as rising musculoskeletal disorders (MSDs), costly turnover, and lost production.
Does your facility face any of these challenges?
- Rising OSHA Recordables: An increase in ergonomic-related incidents, recordables, or lost-time cases tied to repetitive motion, heavy force, or awkward postures.
- Costly Equipment Turnover & Premature Wear: Burning through materials handling equipment—like facility carts, casters, and lifts—at a costly, rapid pace because the equipment doesn’t match the physical realities or force requirements of the floor.
- An Aging Workforce & Sustainability: Veteran employees performing high-force or repetitive tasks face higher fatigue. Ergonomic redesign supports injury prevention, protects invaluable institutional knowledge, and reduces early exits from physically demanding roles.
- High Turnover in Specific Departments: Personnel leaving physically demanding positions because of cumulative strain, fatigue, or discomfort, rather than pay.
- Localized Injury Spikes: Unexpected increases in complaints in a particular production line, workstation, or shift—without a clearly identified root cause.
- Safety Teams Stretched Too Thin: Internal safety professionals who recognize ergonomic risks but lack the bandwidth, specialized expertise, or advanced measurement tools to run a deep task analysis.
- Capital Equipment Creating New Risk: New machinery or automation investments that inadvertently introduce unexpected ergonomic challenges during real-world, live-shift use.
- Engineering or Design Gaps: Workstations and processes designed strictly for output—without full consideration of operator variability, reach zones, posture, or force requirements.
If these challenges sound familiar, an objective assessment gets you to the root cause and provides an immediate, functional roadmap—not just documentation.
Our Core Ergonomic Services
Pacific Ergonomics takes a highly practical, solution-focused approach to assessment. We evaluate tasks, processes, equipment, and workstation design to ensure each component of your operation supports safety, efficiency, and long-term workforce sustainability.
Comprehensive Industrial Ergonomic Risk Assessments
A systematic, objective evaluation of force, posture, repetition, duration, and environmental factors across specific tasks, departments, or full production lines. Our Certified Professional Ergonomists isolate the root causes of musculoskeletal strain and prioritize risks based on operational impact using industry-standard objective metrics.
Blended Workforce Training & Union Integration
Practical training tailored directly to the demands of manufacturing and production environments. To maximize efficiency and eliminate operational downtime, we can blend our ergonomic training modules directly into your existing union-required technical training schedules, seamlessly satisfying collective bargaining requirements while actively lowering injury risks.
AI-Powered Visual SOPs & Video Training
To ensure proper movement patterns stick long after we leave the floor, we deliver customized, AI-enhanced instructional videos. These videos demonstrate exact, correct-posture execution for your specific machinery and lines, serving as a highly visual, easily digestible training reference for new hires and safety refreshers.
Engineering & Workstation Redesign Recommendations
Functional, actionable recommendations ranging from simple, zero-cost workstation adjustments to fully engineered physical controls, equipment modifications, and workflow redesign strategies designed to cut the risk off at the source.
Off-the-Shelf vs. Custom Tool & Equipment Solutions
Not every ergonomic challenge requires a custom engineering project—and not every issue can be solved with a catalog item. We evaluate whether commercially available tools, workstations, or assist devices will effectively reduce risk first to save your budget. When appropriate, we help design, specify, and support the development of tailored modifications built uniquely for your operational environment.
Our 5-Step Functional Process: From Risk to Fix
At Pacific Ergonomics, we believe meaningful change starts with understanding your specific operational environment, not applying generic standards. Every engagement is structured to create forward movement, measurable risk reduction, and operational execution.
1. On-Site Operational & Needs Analysis
We begin with an in-depth review of your work environment, production flow, and task demands. Our Certified Industrial Ergonomists observe operations firsthand and speak directly with employees, supervisors, and safety leadership to understand both physical strain factors and operational constraints. This grounds every recommendation in real-world production requirements, not theoretical models.
2. Detailed Task & Exposure Evaluation
We evaluate specific tasks, workstations, and processes using structured, objective ergonomic analysis methods to assess repetitive motion, awkward postures, forceful exertions, static loading, duration, and frequency. Our goal is to identify root causes of musculoskeletal strain, not just surface-level symptoms.
3. Customized Risk Reduction Solutions
For each identified risk, we develop practical, prioritized recommendations. Solutions may include immediate workstation adjustments, tool modifications, off-the-shelf assist devices, or custom-designed ergonomic interventions. We always determine the most cost-effective path and ensure all improvements align with operational feasibility.
4. Clear, Implementation-Focused Reporting & Video Deliverables
Following the assessment, we deliver a structured, actionable report outlining findings, prioritized risks, and recommended controls. Our documentation is designed to act as a clear, dust-free roadmap for your EHS teams, operations leadership, engineering teams, and capital planning decisions. Alongside the report, we deliver your custom AI training videos, providing a plug-and-play visual library for your training coordinators.
5. Implementation, Blended Training & Ongoing Support
Industrial ergonomics is most effective when recommendations are actively monitored and maintained. We stay involved after the deliverables go out. We work with your training team to integrate our ergonomics components right into your union-mandated technical training paths. We then revisit high-risk areas, check whether the fixes and training are taking hold on the floor, and adjust the plan if needed to ensure sustainable, long-term improvements.
Ready to Strengthen Your Industrial Ergonomics Strategy?
We partner with your safety, engineering, and operations teams to reduce risk exposure, improve task design, and support a healthier, more sustainable workforce, whether you’re addressing rising injuries, preparing for growth, or strengthening your safety program proactively.
Contact Pacific Ergonomics today to move from risk identification to real implementation.