Revolutionizing workplace safety and health with wearable technology

Imagine going to work, lifting heavy equipment for hours, putting stress on your joints and going home to realize you’ll have to do the same thing the next day. That was a reality for many employees at JELD-WEN's Best of Steel (BOS) facility in Germany. Employees particularly struggled with the physically demanding task of handling large metal sheets in the laser cutting area. That led them to looking into a solution that would alleviate potential joint pain and bring innovation to the plant floor at the same time.

As Bruno Silva Guerreiro, a change agent with BOS, explained, "During the process optimization, we couldn't find a technical solution and had to resort to possible aids for the employees, like a second associate to help with tasks. This led us to exoskeleton technology."

The selection process took about one to three months, with the focus on determining the specific support needed—whether for legs, back or arms—and deciding between mechanical or electrical support.

After thorough research and testing, the team found an exoskeleton device aimed at reducing lumbar or shoulder strain during overhead activities and manual handling of weights. The chosen model offers significant support by stabilizing the back and assisting employees in lifting loads. Silva Guerreiro elaborated, "The technology we have in use works mechanically through cables and springs. The advantage of this variant is that the employee doesn’t need to go to the gym after work to prevent muscle degradation."

Implementation and future use

The exoskeleton device was implemented at the end of December 2023, with training sessions held in mid-January 2024 for employees at BOS. Initially, employees were enthusiastic about the new technology. However, some younger colleagues, who were not experiencing shoulder and back issues, were less convinced of its benefits. Silva Guerreiro noted, "The challenge is to explain to them that it is a work relief and a preventive measure to maintain long-term health and work capacity."

The exoskeleton ensures a healthy posture by keeping the shoulders and back in an orthopedically correct position. It also features lumbar padding for a snug fit. "Since the workflow is easier, productivity will not worsen," Silva Guerreiro added.

The exoskeleton device emphasizes JELD-WEN’s commitment to employee health and well-being, promoting a culture of care and support.

"The exoskeleton devices are important for the company as well as employee health. We would like our associates to remain healthy and not be concerned about injuries that could’ve been prevented," Silva Guerreiro said.