Wearable Tech and AI Motion Tools Cut MSD Risk at Major Manufacturers, NSC Program Finds

Companies that piloted emerging ergonomic technologies reported reductions in injury-related costs and vibration exposures, the National Safety Council's MSD Solutions Lab reports.
By: | July 6, 2026
ergonomic data review concept

Musculoskeletal disorders cost U.S. employers more than $17 billion in upper-extremity injuries alone in 2022, and four companies that participated in the National Safety Council’s MSD Solutions Lab 2024-2025 Pilot Grant Program found that wearable sensors, AI-driven motion analytics and vibration-monitoring gloves could meaningfully reduce that burden.

The program paired MSD Pledge member organizations — Superior Tube Products, Ocean Spray Cranberries, PepsiCo and Wonderbrands — with technology providers to test ergonomic solutions in live production environments, with results including a 60% drop in recordable incident rates at one site and a 50% reduction in elevated vibration readings at another.

Technology Surfaces Hidden Risks, Drives Down Costs

Superior Tube Products, a fabricated tubular assembly manufacturer now part of Morton Industries, partnered with 3motionAI to deploy video-based motion capture and an AI risk analytics dashboard across production cells. The pilot ran approximately eight months and produced results that challenged the site’s assumptions about where risk was concentrated.

The team initially believed heavy-tubing operations carried the greatest ergonomic hazard, but analysis revealed those operators used effective techniques and mechanical aids. The actual exposure driver was the wash bay, where an oversized wash wand forced workers into sustained shoulder elevation and extended reach. A replacement wand costing roughly $45 resolved the issue without process redesign.

The financial impact extended well beyond that single fix. Over three years, Superior Tube’s workers’ compensation costs fell by more than 98%, and the facility’s experience modification rate decreased by 36%, according to the report. The total recordable incident rate dropped 60% in one year. The MSD Solutions Lab report noted that these improvements stemmed from shifting ergonomic assessment from informal observation to objective, video-based data that could be reviewed collaboratively with frontline workers and supervisors.

At Ocean Spray Cranberries, roughly 100 employees performing wooden bin repairs with high-vibration power tools faced chronic risk of hand-arm vibration syndrome. The facility partnered with Feraru Dynamics to deploy the company’s HAV-Sentry wearable glove, which monitors vibration amplitude, frequency and duration in real time and alerts workers when exposure approaches recognized safety thresholds.

By matching sensor data to synchronized video footage, supervisors could pinpoint the exact grip technique or cutting behavior behind each spike in readings. Over the pilot period, elevated vibration readings decreased by 50%, the report said, and all participating workers gained measurable training on HAVS risk and proper tool technique, knowledge the site then shared across its broader environmental health and safety network.

Baseline Data Across Shifts Reveals Patterns Traditional Methods Miss

PepsiCo Global Concentrates Solutions and Wonderbrands both used LifeBooster‘s multipoint wearable sensor system and its Senz analytics platform to build ergonomic risk baselines across multiple job categories and shifts.

At the PepsiCo Arlington, Texas, site, 82 full-shift assessments spanning four workgroups generated more than 664 hours of exposure data. Analysis showed that sanitation, salts automated storage and retrieval system, and batching operator roles carried the highest risk scores, ranging from 209 to 335 against a site average of 203, while night-shift workers showed higher overall exposure than day-shift counterparts, likely due to workflow pacing, staffing patterns and less equipment availability.

Back flexion and side bending were the dominant contributors to repetitive strain risk across all roles at the PepsiCo facility. The site implemented four prioritized controls, including pallet leveler tension adjustments and a hose attachment to reduce bending during cleaning tasks, with validation work ongoing.

At Wonderbrands’ Langley, British Columbia, bakery, the wearable approach captured 112 assessments and more than 829 hours of motion data across eight job categories, achieving what the report described as a 95% reduction in data collection time compared to traditional observational methods. Bread line, roll line and scaling roles emerged as highest risk, driven by repetitive upper-body movements and sustained trunk flexion.

Across all four pilots, the MSD Solutions Lab report emphasized that technology functioned as a decision-support tool rather than a standalone solution. Organizations reported the most meaningful progress when sensor data and analytics were paired with structured involvement of frontline workers in identifying and validating controls, an approach the report described as participatory ergonomics.

Obtain the full report here. &

The R&I Editorial Team can be reached at [email protected].

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