Lifting Smart: Ergonomic Techniques for Facility Teams

By Pat Muller, Ready 2 Respond Trainer

Lifting equipment is a routine part of the job in most facilities—but when done incorrectly, it can cause serious injuries that disrupt productivity and can lead to long-term health issues. The solution? Prioritizing ergonomic, safe lifting practices that protect employees, improve efficiency, and reduce costly downtime.

Why Ergonomic Lifting Matters

Lifting equipment improperly can put unnecessary strain on the body, especially the back, shoulders, and knees. According to the Occupational Safety and Health Administration (OSHA), musculoskeletal disorders (MSDs) are among the leading causes of workplace injuries.

By employing ergonomic lifting practices, facility managers can:

• Protect Employee Health: Reduce the risk of workplace injuries such as back strain and joint pain.
• Ensure Operational Efficiency: Avoid downtime caused by injury-related absences.
• Reduce Costs: Minimize medical expenses and workers’ compensation claims associated with lifting-related injuries.
• Comply with Regulations: Maintain OSHA compliance and create a safer workplace environment.

Common Risks When Lifting Equipment

Lifting equipment without proper precautions can lead to a range of injuries and long-term complications. Some of the most common risks include:

• Excessive Weight: Lifting items that exceed safe limits increases the chance of strain or injury.
• Improper Posture: Twisting or bending incorrectly can stress muscles and ligaments.
• Repetitive Tasks: Frequent lifting over time can cause chronic overuse injuries.
• Insufficient Training: Without proper instruction, employees may use incorrect techniques or misuse lifting equipment.

Recognizing these risks is a critical first step toward creating a safer and more productive workplace.

The Ergonomic Lifting Checklist

To ensure safe lifting practices, facility managers should encourage their teams to follow these ergonomic lifting guidelines:

1. Assess the Load

Safe lifting starts with evaluating the load before attempting to move it. If an item is too heavy, bulky, or awkwardly shaped, it increases the risk of injury. According to OSHA guidelines, individuals should avoid lifting items that weigh more than 50 pounds without assistance.

2. Plan the Lift

Ensure the pathway is clear of hazards such as loose cords, wet floors, or clutter. Identify where the load needs to go and how you will safely move it there. For heavier or oversized equipment—use appropriate tools such as dollies, forklifts, or cranes—or coordinate a team lift to reduce strain and improve safety.

3. Use Proper Posture

One of the biggest causes of lifting-related injuries is poor posture. To prevent back strain, train team members to:

• Bend at the hips and knees, not the waist.
• Keep the back straight, chest up, and shoulders aligned.
• Engage the legs, not the back, when lifting.

Demonstrate proper lifting techniques during safety meetings, as hands-on practice ensures teams remember the correct form.

4. Utilize Tools and Equipment

Invest in ergonomic tools specifically designed for lifting heavy or awkward objects. Some examples include:

• Lift-assist devices such as hoists or conveyors for large equipment.
• Ergonomic dollies and carts, which can minimize strain during transport.

Training teams on using these tools properly will add an extra layer of safety to facility operations.

5. Take Breaks

For repetitive lifting tasks, schedule regular breaks to allow muscles to recover. Prolonged exertion increases the risk of fatigue, heightening the likelihood of injury.

6. Train the Team

Consistent training in ergonomic lifting techniques is essential to maintaining a safe work environment. Regular workshops or sessions led by safety consultants help ensure all team members understand how to lift and move equipment properly. Encouraging ongoing feedback and open discussions around workplace safety can further strengthen practices and help identify risks before they lead to injury.

Building a Culture of Safety

An effective ergonomics program goes beyond a single set of instructions. Facility managers should establish a culture that prioritizes safety at all levels. This includes:

• Regular safety audits to assess how lifting tasks are performed and address any unsafe practices.
• Encouraging employees to report hazards or unsafe conditions without fear of repercussions.
• Celebrating team efforts when safety policies are followed.

The Long-Term Impact of Ergonomic Lifting

Lifting may seem simple, but getting it wrong can cause serious injuries and costly downtime. By combining smart lifting techniques, ergonomic tools, and a proactive safety culture, facility managers can protect team members, boost efficiency, and prevent workplace injuries.

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