Musculoskeletal risk is the slowest-moving hazard in industry: no alarm, no incident report, just cumulative load that surfaces as injuries, absenteeism, and compensation claims years later. The assessment methodologies that catch it early have existed for decades. What has not existed is a way to apply them at the scale of an actual plant — hundreds of workstations, three shifts, tasks that change with every product variant.

A manual assessment campaign samples a handful of stations on a good day, scores the postures the assessor happens to observe, and produces a report weeks later. By the time it lands, the line has changed. This is nobody's failure — it is arithmetic. One expert, one clipboard, one workstation at a time cannot cover a facility.

What automation actually changes

  • Coverage: a short video of any task, from any camera — a phone works — becomes an assessable record. Every workstation can be scored, not a sample.
  • Consistency: posture is scored frame by frame against the standard methodologies, the same way every time, with no observer variation.
  • Speed: an assessor-grade report with prioritized, engineering-first fixes arrives in minutes, while the line it describes still exists.
  • Evidence: findings anchor to specific frames with the worst-case postures highlighted, so the report shows its work.
  • Repeatability: after a fix, reassessing is another short video — before and after, measured the same way.

Rigor is preserved, not shortcut: every assessment is challenged by a second AI layer that critiques the result against the actual scene before the report ships, and every condition that shaped the assessment is declared on the first page. Privacy is handled by construction — faces are anonymized, footage is processed and then deleted, and the evidence that remains is the posture record, not the person.

In production, not in pilot

ERGO runs this workflow today at one of India's largest automotive components conglomerates: paid, recurring assessments across production workstations, with per-worker scoring on team tasks and prioritized corrective actions tied to projected risk reduction. The output is deliberately practical — a work order with target specifications, not a lecture.

If your last plant-wide ergonomic assessment is more than a year old — or was never plant-wide at all — the pilot costs one short video of your highest-risk task. Record it, upload it, and read what comes back.