Distribution Center Decreased High-Risk Movement with Wearable Technology Program

The Challenge

Employees at a global beverage distribution company were experiencing increasing levels of musculoskeletal discomfort caused by repetitive bending, twisting, and reaching during physically demanding daily tasks. Because employees spent much of their time traveling between delivery locations and performing work in constantly changing environments, traditional ergonomic observation methods proved difficult to scale and limited the company’s ability to consistently capture accurate movement data in the field.

Without objective visibility into how and when employees were working in unsafe postures, the organization faced challenges identifying the highest-risk movements and implementing targeted ergonomic improvements. The company needed a more innovative, data-driven solution that could quantify high-risk movements in real working conditions while helping employees improve movement behaviors in real time.

The Solution

To proactively reduce injury risk and improve workforce safety, the company partnered with Briotix Health to implement advanced wearable technology capable of capturing real-time biomechanical movement data and transforming it into actionable ergonomic insights.

The program rolled out in three steps: 

DEVICE IDENTIFICATION

Following an evaluation of employee job tasks and movement demands, Briotix Health identified the most appropriate wearable technology solution to monitor the specific high-risk motions contributing to discomfort and injury potential. The devices were selected to accurately measure bending, twisting, and reaching frequency, duration, and severity during daily operations. 

BASELINE TESTING AND PILOT

Baseline data collection established a clear understanding of how frequently employees were performing unsafe movements before intervention. Briotix Health then launched a four-week pilot program that combined wearable sensor technology with instant haptic feedback, alerting employees in real time when unsafe postures occurred. This immediate feedback loop, paired with follow-up coaching from Briotix Health biomechanics experts, helped employees make meaningful movement adjustments while performing their normal job tasks. 

DATA ANALYSIS

At the conclusion of the pilot, Briotix Health analyzed and compared data against baseline measurements to quantify behavioral improvements and ergonomic risk reduction. The results demonstrated significant decreases in high-risk posture frequency, duration, and severity, validating the effectiveness of combining wearable technology with personalized ergonomic coaching. 

The Results

The pilot program produced measurable improvements in employee movement behaviors, resulting in a 34% reduction in unsafe body angles and high-risk postures during daily work activities. Additionally, the program was projected to eliminate approximately 9,500 high-risk postures per worker annually, significantly reducing ergonomic exposure while supporting safer, more sustainable work practices.

Beyond immediate posture improvements, the wearable technology solution also provided long-term strategic value by enabling the company to:

• Prioritize ergonomic support and intervention resources for the highest-risk employees and locations
• Identify employees who would benefit from additional observation, coaching, education, or movement training
• Develop data-driven standards for work volume, task rotation, and route organization
• Establish a proactive, technology-enabled approach to injury prevention and ergonomic risk management across operations