Published: July 2025
Forklift Cab Ergonomics: What HR Teams Need to Know to Protect Operators and Reduce Injury
Workplace safety isn’t just a compliance issue—it’s an HR priority. For companies that rely on forklifts, one of the most overlooked safety risks is cab ergonomics. Poor posture, repetitive motion, and awkward entry/exit design can all contribute to musculoskeletal disorders (MSDs), decreased productivity, and higher turnover. The CDC conducted a research investigation on MSD cases relating to poor forklift ergonomics during the summer of 2012. The results showed just how much day-to-day twisting and vibrations harms operators.
As HR professionals take a more active role in shaping workplace health and wellness programs, understanding forklift cab ergonomics becomes essential. It’s a key area where smart investments can protect workers, improve job satisfaction, and reduce claims.
Forklift operators often spend 6 to 10 hours a day seated, navigating tight spaces, and making repetitive steering and lifting motions. Over time, that physical strain adds up. According to the Bureau of Labor Statistics, operators of industrial trucks and tractors have one of the highest rates of work-related musculoskeletal injuries in the private sector.
Proper ergonomic design and setup in forklift cabs can help prevent:
When evaluating or upgrading your forklift fleet, HR teams should be aware of the following features that improve ergonomics:
HR teams are uniquely positioned to champion ergonomic improvements. Here’s how:
While industrial lifts and warehouses are not cushy places by any means, the prioritization of ergonomics enables operators to focus on their tasks, prevent long-term injury and discomfort, and allow better flexibility within job positions. Modern Materials Handling recently interviewed Michael Brunnet of Mitsubishi Logisnext to get the inside opinion on ergonomics. To summarize, Brunnet said “at the end of the day, having a happy operator, a comfortable operator, along with the right safety protocols, will allow them to be more efficient and will allow them to be able to move more material throughout the day.”
By taking ergonomics seriously, HR teams can be proactive partners in injury prevention and operator well-being. With the right equipment, training, and communication, forklift-related strain doesn’t have to be an unavoidable part of the job.
Q: How often should forklift cab ergonomics be evaluated?
A: At minimum, whenever new equipment is introduced or injuries are reported. Annual reviews are recommended as part of a broader safety assessment.
Q: Can poor cab ergonomics really lead to long-term injury?
A: Yes. Repetitive strain and poor posture are linked to chronic issues like herniated discs, tendonitis, and carpal tunnel syndrome. Long-term exposure to loud sounds as well as vibrations can contribute to hearing issues and circulation problems.
Q: What role does HR play in forklift operator safety?
A: HR can integrate ergonomic safety into wellness initiatives, assist in policy development, and ensure proper documentation and training.
Q: Are ergonomic forklifts more expensive?
A: Initially, they may cost more, but they often deliver long-term ROI through reduced injuries, fewer workers' comp claims, and improved operator retention.