Protect seasonal workers using AI

ONE OF the most effective ways to train large workforces in accident and injury prevention is through the use of AI wearable technology.  These devices have a proven record of reducing accident rates, maintaining worker wellbeing, and enhancing health and safety (H&S) training. Artificial intelligence (AI) is a key player in this transformation, giving training managers the ability for the first time to collect real-time detailed data about workplace environments and individual task activity. As a primary driver of change in the sector, AI technology can be used to identify risky behaviours and movements, which can be corrected through haptic wearable devices and targeted training. Also the data can be used by managers to refine shift patterns, workloads, training programmes and planning.

How does the technology work?

According to the latest figures from the Health and Safety Executive, 543,000 workers in the UK  suffered from work-related MSDs in 2023/24, with 7.8 million working days lost due to these conditions, which are predominantly back injuries. Musculoskeletal Disorders (MSDs)  are a leading cause of workplace sickness and can really affect a business’s bottom line with new workers being particularly at risk. Wearable technologies such as the Modjoul SmartBelt, use technology designed to bring about behavioural change and reduce workplace injury. The SmartBelt device is worn by the worker and produces a haptic buzz reminding them to correct their posture when bending, lifting or twisting in a way that might cause injury.

SmartBelts can closely monitor any predicted unsafe movements  and research has found that these types of risky movements decline rapidly within hours of use as new behaviours form due to feedback received via the device. The data generated from each of these individual movements is recorded and analysed by an AI platform to help build a bespoke pattern of risk and to see if there are emerging trends from the data model. 

The same applies to exoskeleton technology such as the WearHealth exoskeleton ergonomics AI technology, which matches the right exoskeleton suit to the physical activity being performed by the worker. Video scanning devices are used to assess specific tasks and recommend the most suitable exoskeleton suit from the many that are on the market.  A detailed report is then prepared by AI analysis and health and safety assessors, who will curate the data and provide comparison statistics showing risk reduction before and after the technology is deployed.  This allows the employer to make an informed decision about the best way forward.

Creating a safer workplace environment

Wearable devices are extremely versatile, and the technology can be used for a variety of purposes. For example, the Modjoul SmartBelt has the ability to communicate with forklift drivers and nearby workers to help prevent workplace collisions. If a forklift is nearby, the technology alerts both the driver and the worker ensuring that they are able to avoid each other. This is particularly useful in areas with restricted visibility such as blind corners. It will also provide reassurance  to workers who are less experienced, ensuring safer operations in workplaces like warehouses and logistics hubs, where workers and machinery need to co-exist safely.  Data reporting driven from the Cloud can deliver granular details of near misses and alternative routing.

Temperature controlled environments are often a feature of food led workplaces and SmartBelt technology can also be used to monitor workers’ exposure to extreme temperatures. The device alerts the user if they have spent too long at an unsafe temperature, allowing them to remove themselves to a more temperate area. It can also monitor light and sound levels and tell the user if they have been working in an environment that is too light or too dark, or too noisy.

Protecting workers – a real life example

Construction supplier TECHNAL approached Stanley to discuss wearable technology solutions to help with issues that their workers were having when lifting heavy metal profiles from racking and getting them ready to dispatch to customers. These profiles weigh anything from 10-30kg and sometimes the operatives need to bend low into racking to pick them up and then hoist them up onto their shoulders. The two main shop floor workers both have back and knee issues caused by constant lifting and stretching and instantly felt a benefit from using  a Stanley supplied exoskeleton when handling products such as curtain walling, sliding doors and girders.

Andre Jutel, Solutions Consultant at Stanley said: “It was interesting to see the results on the workers involved – one of whom was in his 60s and the other in his 20s.  Both felt an immediate benefit from wearing the exoskeletons, which are designed to provide back support when lifting heavy loads.  Anecdotally, both workers reported instant relief, especially in the case of the younger worker who commented that he immediately felt less pain, less fatigue and went home feeling better and would happily wear one all the time while on shift.  

The analysis report done for TECHNAL included a precise assessment of core activities and provided data-driven insights that proved the effectiveness of the exoskeleton suit in enhancing worker safety.  The key results of that analysis show that using the exoskeleton technology could potentially reduce lower back injuries at work by 30%.  

TECHNAL now plan to purchase two further exosuits as they continue to monitor the results going forward.

Developing bespoke training plans

A key benefit of AI wearable devices is their ability to analyse and find patterns in historical data on manual handling tasks, workplace conditions, and injury records. This can be used to help identify issues and pinpoint high-risk situations or tasks prone to injuries. By factoring these insights into health and safety training, a safer work environment can be developed. The granular nature of the data generated by these wearable technologies enables precise and targeted training regimes, significantly reducing accidents. 

Weak points identified from the data can help organisations to develop comprehensive health and safety training plans. For example, wearable technology statistics show that within the first two months of employment, there is a 70% increased risk of injury and that 1 in 8 of all workplace injuries happen on an employee’s first week on the job. This may be a particular issue for organisations that employ a large number of temporary or seasonal workers. Because the wearable technologies can quickly and easily assess high-risk manual tasks, HR managers can design more targeting training programmes for these situations, that can be used alongside the smart devices to reinforce safer movements and provide real time feedback helping workers to develop and maintain good ergonomic habits. 

The devices all have customisable dashboards which allow for data collection in real-time so managers can pinpoint exactly where the potential risks are and what progress is being made. The changes can be tracked using real-time data, target setting, and ongoing assessments.

Return on investment

AI wearable technology is here to stay and those organisations that have invested, are reaping the benefits in terms of fewer accidents and injuries and improved productivity and efficiency. The wealth of detailed data provided by wearables is game changing, allowing businesses to track improvements in real time - ultimately transforming staff health and wellbeing.

Graham Sharp, managing director of health and safety consultancy, Stanley

For more information, visit www.stanleyhandling.co.uk