Workplace injuries remain a persistent challenge across industries—from warehouses and manufacturing floors to healthcare and construction. While companies invest heavily in PPE, training, and compliance checks, one issue continues to undermine their efforts: underreporting. When incidents go unnoticed or unacknowledged, the chance to address them slips away. This is especially true for injuries that develop gradually, such as musculoskeletal disorders (MSDs).
According to Protex AI’s workplace safety data, a third of workers experience musculoskeletal disorders, yet many cases are never formally documented. This disconnect between reality and reporting threatens not only worker health but also an organisation’s ability to respond proactively. Closing this gap requires cultural, technological, and procedural changes—led by EHS teams and supported from the top down.
Understanding Musculoskeletal Disorders in the Workplace
MSDs include injuries to muscles, tendons, ligaments, and nerves. They’re often caused by repetitive strain, awkward postures, manual handling, or vibration exposure. These types of injuries develop over time, meaning workers might delay reporting them or not report them at all—until the pain becomes unbearable or leads to missed work.
Industries like logistics, manufacturing, and retail see particularly high rates of MSDs due to frequent lifting, prolonged standing, and repetitive motions. Early intervention is key, but when workers feel discouraged or unsure about how to report symptoms, injuries worsen and lead to long-term consequences.
Why MSDs Often Go Unreported
There are several reasons why musculoskeletal injuries don’t make it into official records. One common issue is normalisation—many workers view aches and pains as “part of the job,” especially in physically demanding roles. This mindset leads to underreporting, which distorts safety data and hinders intervention.
Another barrier is the stigma associated with reporting. Employees may fear being labelled as complainers or worry about job security if they speak up. Others simply don’t know that minor symptoms can qualify as reportable concerns.
Finally, the complexity or slowness of internal reporting processes can discourage employees from taking action. If a worker needs to fill out a paper form, locate a supervisor, and wait days for follow-up, the pain may be easier to ignore—until it escalates.
The Role of Leadership in Encouraging Early Reporting
Safety culture starts with leadership. When senior managers and supervisors actively encourage early reporting, the entire organisation becomes more alert and responsive. Leaders must communicate that all injuries matter, including those that aren’t immediately visible or dramatic.
Routine check-ins, open-door policies, and visible support for safety reporting can significantly improve participation. Workers need to believe that their concerns will be taken seriously and acted upon without negative consequences.
Digital Tools for Identifying and Tracking MSDs
Modern safety platforms are increasingly capable of detecting early signs of MSD risk. AI-powered video analytics, for example, can monitor posture, lifting mechanics, and repetitive movements to flag ergonomic risks before they lead to injury.
These systems allow safety teams to track trends over time. Are workers frequently bending incorrectly? Are certain shifts or roles more prone to awkward movements? With this level of insight, EHS managers can redesign workflows, adjust training, and implement engineering controls—turning reactive responses into proactive interventions.
Additionally, integrating digital reporting tools such as mobile apps and wearable sensors empowers workers to log symptoms in real time. This streamlines the process, reduces the burden, and ensures that more data makes its way to safety leaders who can act on it.
Training and Ergonomics Education
Even with the best technology, human awareness is critical. Training programmes focused on body mechanics, safe lifting techniques, and posture awareness remain one of the most cost-effective ways to prevent MSDs.
Companies should offer onboarding ergonomics training as well as refresher courses. These sessions should include interactive components—such as demonstrations or virtual simulations—that allow employees to practise safe techniques and understand the consequences of poor ergonomics.
Importantly, ergonomics training should be adapted to the specific tasks performed in the workplace. A one-size-fits-all approach is rarely effective. When training is customised, workers are more likely to remember and apply what they’ve learned.
Measuring the Impact of Early Reporting
One of the most compelling arguments for improving MSD reporting is the measurable impact it can have. Companies that act quickly on ergonomic concerns tend to see a marked reduction in lost workdays, compensation claims, and employee turnover.
When data from incident reports is analysed alongside environmental and task-based risk factors, safety leaders gain a clearer picture of the root causes. They can then introduce targeted changes—such as adjustable workstations, job rotation schedules, or redesigned tools—to reduce strain and discomfort.
These small changes compound over time. A 5% reduction in MSD-related absences might not seem like much in isolation, but it represents significant cost savings and improved productivity across the year.
Promoting a Culture of Continuous Feedback
Encouraging workers to report MSD symptoms early is not a one-time initiative—it requires sustained effort and cultural reinforcement. Organisations should consider implementing anonymous feedback channels, suggestion boxes, or digital kiosks to capture ongoing insights from staff.
Supervisors and safety reps should regularly walk the floor, asking open-ended questions like “Have you noticed any new strains or pains recently?” or “Is there any equipment that feels awkward or uncomfortable to use?”
These conversations build trust and demonstrate that management values employee well-being. They also increase the likelihood that small issues are addressed before they escalate into recordable injuries.
Building Momentum with Data Transparency
Transparency around injury trends and corrective actions can help motivate workers to participate in reporting efforts. By sharing anonymised data in team meetings or on internal dashboards, companies show that reports lead to real improvements.
For example, if multiple workers in one department report shoulder strain and the company responds by adjusting shelving height, that story should be shared. It reinforces the value of speaking up and builds a virtuous cycle of feedback, response, and improvement.
Ultimately, the goal is to create a workplace where injury prevention is everyone’s responsibility and where even the earliest symptoms of strain are taken seriously.
With a third of workers experience musculoskeletal disorders, early reporting of ergonomic risks must be a priority. By making reporting easier, safer, and more impactful, companies can dramatically reduce injuries and create a more resilient safety culture.
Comments are closed.