The True Cost of Poor Ergonomics: Why Early Intervention Matters

Kendra S.
Apr 17
4 min read

Up to 38% of all workplace injuries in Canada are related to musculoskeletal disorders (MSDs), and they account for nearly half of all lost-time claims—yet many of these injuries develop gradually and go unreported until they become severe. — **Up to 38% of all workplace injuries in Canada are related to musculoskeletal disorders (MSDs),** and they account for **nearly half of all lost-time claims**—yet many of these injuries develop gradually and go unreported until they become severe.

For many employers, ergonomic injuries are seen as an inevitable cost of doing business—particularly in sectors like manufacturing, healthcare, logistics, and construction. But the reality is that most musculoskeletal injuries (MSIs) are preventable. And when they’re not prevented, the consequences—both human and financial—can be significant.

As more organizations face rising workers’ compensation costs, productivity losses, and increasing absenteeism, proactive ergonomic risk management is no longer optional. It’s a strategic imperative.

Understanding the Scope: What Is an Ergonomic Injury?

Musculoskeletal injuries occur when muscles, tendons, ligaments, or joints are subjected to excessive or repetitive strain. These injuries often develop slowly over time due to poor posture, awkward lifting, repetitive motion, or inadequate workstation design.

WorkSafeBC defines MSIs as injuries that affect the body’s movement or musculoskeletal system, and they account for a significant proportion of all time-loss injuries in Canada. These include:

Back strains from lifting heavy loads incorrectly
Neck and shoulder pain from poor desk posture
Repetitive strain injuries (RSIs) like carpal tunnel syndrome
Knee and hip issues from frequent squatting or twisting

In many cases, the worker may not even realize they are at risk—until the injury has already occurred.

The Financial Impact of Poor Ergonomics

The direct costs of ergonomic injuries are well-documented: workers’ compensation claims, medical treatment, rehabilitation, and lost wages. However, the indirect costs are often even more substantial and frequently underestimated. These include:

Lost productivity due to modified duties or absenteeism
Increased overtime to compensate for injured employees
Training costs for replacement workers
Legal and insurance costs
Reduced morale and engagement across teams

According to data from the Association of Workers’ Compensation Boards of Canada (AWCBC), musculoskeletal injuries represented more than 43 per cent of all lost-time claims in 2022. In British Columbia alone, WorkSafeBC reported that over one-third of all injury claims are MSIs, costing the province hundreds of millions annually.

(Source: AWCBC Key Statistical Measures; WorkSafeBC – Ergonomics)

Moreover, the National Safety Council (NSC) in the United States estimates that the average direct cost per ergonomic injury is over $20,000 CAD, with indirect costs potentially three to four times higher.

The Case for Early Intervention

Ergonomic issues tend to escalate when left unaddressed. What starts as occasional discomfort can evolve into chronic pain and long-term disability. Once the injury becomes symptomatic, both the recovery timeline and associated costs increase dramatically.

Early intervention—identifying high-risk postures and tasks before symptoms arise—has been proven to:

Reduce the frequency and severity of injuries
Lower overall compensation claims
Support faster return-to-work outcomes
Preserve workforce continuity and institutional knowledge

The Institute for Work & Health has found strong evidence that workplace ergonomic interventions lead to reduced symptoms and improved functional outcomes for employees. Participatory ergonomics programs, in particular—where workers are directly involved in identifying and solving ergonomic risks—consistently lead to safer outcomes and higher adoption rates.

(Source: Institute for Work & Health – Ergonomics)

Investing in Prevention: What the Research Says

A report by the Canadian Centre for Occupational Health and Safety (CCOHS) highlights that organizations that adopt ergonomic strategies as part of their health and safety management systems often see a return on investment (ROI) in the form of:

Fewer injuries and claims
Improved employee satisfaction and retention
Higher operational efficiency

The ROI of ergonomic programs is consistently positive. According to a meta-analysis of 250 ergonomic case studies by the Washington State Department of Labor & Industries, the median benefit-cost ratio of ergonomic interventions was 2.2:1, meaning every dollar invested returned over two dollars in savings.

(Source: Washington State L&I – Ergonomics Case Studies)

The Role of Technology: How Vergo Supports Early Action

Traditional ergonomic assessments rely on in-person evaluations by specialists—a valuable but time-consuming and limited resource. Vergo’s AI-powered platform provides a scalable, accessible solution that allows companies to assess posture and movement risks using short video clips of real work tasks.

Vergo offers:

Computer vision-based posture detection using video
Automated ergonomic scoring aligned with industry frameworks
Clear visuals and reports to identify high-risk movements
A library of microlearning videos to guide behaviour change over time

This approach empowers safety professionals to flag issues early—without waiting for injuries to appear—and promotes a culture of continuous improvement. It also allows data to be collected and tracked over time, which is particularly useful for high-turnover or seasonal workforces.

Ergonomics as a Business Priority

Workplace injuries related to poor ergonomics are not only preventable—they are predictable. And the earlier a business intervenes, the better the outcomes for its employees and its bottom line.

By treating ergonomics as a strategic investment rather than a compliance checkbox, organizations can reduce injury claims, increase productivity, and create safer, more engaged work environments. With tools like Vergo, prevention is no longer out of reach—it’s a practical, measurable advantage.