Minimizing Injury Risk in the Bending Department

BLS

Proactive Planning & Employee Engagement Key to Safety

The bending department often acts as a bottleneck in metal fabrication, making injury prevention crucial to keeping operations smooth. With an aging workforce—over 51% of U.S. manufacturing jobs held by workers 45 and older—ergonomic improvements and proactive safety measures are more critical than ever.

Addressing Musculoskeletal Disorders (MSDs)

Press brake operators are at high risk for MSD injuries due to repetitive motions, awkward postures, and handling heavy materials. The Bureau of Labor Statistics reported 502,380 MSD incidents in 2021-2022, with affected workers requiring an average of 14 days off and an additional 20 days of restricted activity. Direct costs from MSD injuries are estimated at $20 billion annually, while indirect costs—lost productivity and training replacements—can be five times higher.

Key Strategies to Reduce Injury Risk

• Match the Job to the Employee: Adjust workstations based on operator height and physical ability. Use lifts, mechanical assist devices, and ergonomic tables to minimize strain.
• Improve Lighting: Poor lighting can cause awkward postures, increasing injury risk—especially for older workers.
• Engage with Operators: Direct feedback from workers helps identify ergonomic concerns and potential hazards. Implementing changes based on employee input fosters a safety-first culture.
• Optimize Layout & Workflow: Ensure sufficient space for movement, install ergonomic controls, and consider crane or lift-assist mechanisms for handling large parts.
• Utilize Safety Resources: Insurance providers, OSHA, and trade organizations offer guidance on press brake safety, ergonomic best practices, and industry safety programs.

By prioritizing ergonomics and employee engagement, metal fabricators can minimize injuries, improve productivity, and enhance workforce retention.