5 Common Ergonomic Mistakes You're Probably Making at Work (and How to Fix Them)

Shen L.
Apr 17
4 min read

Updated: Apr 17

When we think about workplace injuries, we often imagine sudden accidents—falls, slips, or equipment malfunctions. But the truth is, some of the most costly and debilitating injuries happen slowly and silently, through repeated exposure to poor ergonomic conditions.

Across industries, musculoskeletal injuries (MSIs) are the number one cause of lost-time claims in Canada. They are also among the most preventable. Yet many workplaces overlook early warning signs—discomfort, fatigue, and poor posture habits—until it’s too late.

At Vergo, we’ve analyzed hundreds of workplace videos across a range of industries—from manufacturing and logistics to healthcare and construction—and the same ergonomic mistakes appear again and again.

This post outlines five of the most common ergonomic issues we see, how they contribute to workplace injuries, and how to address them before they escalate.

1. Lifting with Your Back Instead of Your Legs

The mistake: Workers bend forward at the waist to lift boxes, tools, or equipment—placing all the strain on the lower back instead of distributing it through the legs and core.

Why it matters: Back injuries are among the most common—and expensive—workplace injuries in Canada. According to WorkSafeBC, over 20% of time-loss claims are caused by overexertion, primarily from improper lifting.

Real-world example: In a warehouse setting we recently assessed, a worker lifted 30–50 boxes per shift using poor form. Within weeks, the individual began experiencing chronic lumbar discomfort—eventually leading to time off and a temporary reassignment to modified duties.

Fix it:

Position yourself close to the object before lifting
Bend at the hips and knees, not the spine
Keep the object close to your body
Engage your core and lift using your legs
Avoid twisting while carrying—pivot with your feet instead

2. Static Sitting or Standing Posture for Extended Periods

The mistake: Employees remain in a fixed position—seated or standing—for hours at a time, often with poor posture and little to no movement.

Why it matters: Prolonged static postures reduce blood circulation and place strain on the spine, shoulders, hips, and lower limbs. Office workers slouching at their desks and factory workers locked in standing positions both face elevated risks of MSIs.

Research insight: According to the Canadian Centre for Occupational Health and Safety (CCOHS), static postures lead to fatigue and discomfort, and significantly increase the likelihood of developing repetitive strain injuries.

Fix it:

Incorporate microbreaks every 30–45 minutes to stretch and move
Use sit-stand desks or footrests for posture variation
Adjust screens to eye level and keyboards to elbow height
Ensure chairs provide adequate lumbar support and allow feet to rest flat on the floor

3. Repetitive Tasks Without Variation or Recovery

The mistake: Tasks requiring frequent hand, wrist, shoulder, or arm motions—like scanning items, assembling parts, or data entry—are performed over and over without variation or rest.

Why it matters: Overuse of the same muscle groups leads to inflammation and conditions such as carpal tunnel syndrome, tendonitis, and rotator cuff injuries. These injuries are difficult to treat and often require long recovery periods.

Industry insight: In manufacturing environments, repetitive strain injuries account for a large percentage of MSIs. In one Ontario-based facility, introducing rotation between inspection, packaging, and loading roles helped cut RSI-related complaints in half within three months.

Fix it:

Rotate tasks where possible to spread the load across different muscle groups
Use ergonomic tools (e.g., padded handles, adjustable work surfaces)
Incorporate stretching into daily routines
Monitor employees for early signs of fatigue or discomfort and adjust workloads accordingly

4. Awkward Reaching or Overhead Work

The mistake: Workers repeatedly reach above shoulder level or stretch across workstations to access tools, equipment, or supplies.

Why it matters: Reaching beyond the body’s neutral posture stresses the shoulders, neck, and upper back, increasing the risk of muscle strain and fatigue. Overhead work, especially when paired with load handling, is a major contributor to shoulder injuries.

Data insight: Studies published by the Institute for Work & Health show that tasks requiring the arms to be held overhead for extended periods can significantly increase the risk of rotator cuff injuries and muscle fatigue.

Fix it:

Keep frequently used tools within easy reach (within forearm distance)
Reconfigure workstations to minimize stretching and leaning
Use step stools or adjustable platforms for overhead tasks
Consider mechanical aids or jigs to bring items to a more neutral position

5. Ignoring Discomfort or Early Warning Signs

The mistake:Employees feel discomfort—tingling, stiffness, fatigue—but fail to report it or modify their behaviour, assuming it’s just “part of the job.”

Why it matters:Pain is often the final warning sign of an underlying issue. Ignoring early signs of strain allows the problem to worsen, potentially leading to chronic conditions, disability claims, or long-term job reassignment.

Case insight:In one healthcare facility we reviewed, nursing staff reported shoulder soreness for weeks before an ergonomic assessment was conducted. By then, two workers had already filed WCB claims related to overuse injuries from patient handling tasks.

Fix it:

Create a culture where workers feel comfortable reporting discomfort
Use tools like Vergo to conduct regular assessments and flag risks early
Address early complaints with adjustments and proactive support
Track reported issues and link them to task design improvements

How Vergo Helps Break the Cycle

Vergo’s AI-powered ergonomics platform is built specifically to address these recurring issues. By allowing organizations to record short clips of real workplace movements and automatically assessing posture, joint angles, and risk scores, Vergo empowers teams to:

Identify high-risk postures and tasks before injuries occur
Deliver personalized insights and corrective suggestions
Track progress over time with clear visual feedback
Educate employees through bite-sized training videos that build long-term habits

Whether you're managing a team in logistics, construction, healthcare, or manufacturing, Vergo’s tools make it easier to protect your workforce and reduce your injury-related costs.