Apparel company Carhartt has successfully reduced its OSHA recordable incidents by over 50% through the implementation of an industrial ergonomics program. The program, which was launched in partnership with VelocityEHS, focused on reducing the risk of musculoskeletal disorders (MSDs) for Carhartt’s manufacturing facility employees.

The industrial ergonomics program was first implemented by Carhartt in 2022 at its Irvine, KY facility, with subsequent rollouts at the company’s Camden, TN and Edmonton, KY facilities in 2023 and 2024. Carhartt’s decision to proactively address ergonomics risk factors was driven by a desire to protect its employees from the high rates of MSDs associated with the manufacturing and construction sectors. In particular, Carhartt sought to address the specific risk factors for MSDs that are present in the production of their heavy-duty workwear, such as forceful exertions and repetitive motions.

As part of the industrial ergonomics program, Carhartt partnered with VelocityEHS to implement a technology-driven solution for assessing and mitigating ergonomics risks. This included the use of artificial intelligence (AI) to conduct ergonomic assessments and the development of a 3D model for assessing and analyzing employee movements. The program also involved the formation of ergonomics committees at each facility, which were responsible for conducting MSD risk assessments and developing and implementing solutions to address high-risk activities.

“Establishing a formal ergonomics management system and leveraging technology to guide you along the way is the best way to achieve desired outcomes and improve overall employee engagement, health, wellness and safety performance”, said Matt Airhart, CEO, VelocityEHS.

Carhartt’s investment in an industrial ergonomics program has not only led to a significant reduction in OSHA recordable incidents, but has also generated a positive return on investment for the company. By proactively addressing ergonomics risk factors and reducing the incidence of MSDs, Carhartt has been able to minimize the direct and indirect costs associated with workplace injuries. The company has also seen a number of non-safety related benefits from the program, including increased employee morale and productivity.

“Seeing a high-risk movement reduced to a low-risk movement was rewarding.” said Scott Harper, U.S. Safety Manager at Carhartt. “We knew the ergonomics program would be a success because Velocity wasn’t going to let us fail."

Moving forward, Carhartt plans to continue the expansion of its industrial ergonomics program and the integration of ergonomics principles into its overall health and safety management system. The company will also look for opportunities to further leverage the use of data and technology to drive continuous improvement efforts and ensure the long-term success and sustainability of the program.