Match passive and powered exoskeleton types to specific manual handling and overhead work tasks.
Occupational Health & Safety
Evaluating Industrial Exoskeletons for Manual Handling and Overhead Work
Equips ergonomists and safety professionals to trial, measure and select passive and powered exoskeletons that reduce back and shoulder loading in manual handling and overhead tasks.
🗓️Duration5 training days
📚Content4 modules · 8 sessions
🎓On completionAccredited attendance certificate
About the programme
Course Overview
Manual handling and overhead work remain leading causes of musculoskeletal disorders, and exoskeletons are increasingly marketed as a way to reduce spinal and shoulder loading, yet real performance varies by task, device design and individual fit, and a poorly chosen device can introduce new risks such as balance loss, pinch points or muscle deconditioning. This course applies ISO/TR 22100-5 guidance on exoskeletons alongside practical ergonomic method to differentiate passive spring-based and powered exoskeleton designs, match device type to specific tasks, screen workers for medical contraindications, and run structured pilot trials using perceived exertion and task performance measures. Participants also learn to identify secondary risks, build a device comparison scorecard, and design a procurement and monitoring programme for the period after roll-out. Teaching combines task analysis exercises, device trial protocol design and a device-comparison scorecard exercise, so participants leave able to run a defensible pilot and avoid selecting an unsuitable device.
Expected Learning Outcomes
Design a structured pilot trial that measures perceived exertion and task performance before wider adoption.
Screen workers for medical contraindications and fit issues before exoskeleton use begins.
Identify secondary risks introduced by exoskeleton use, including balance loss, pinch points and muscle deconditioning.
Apply ISO/TR 22100-5 to assess the interaction between exoskeletons and existing machinery risk assessments.
Build a device comparison scorecard covering support level, adjustability, comfort and task compatibility.
Establish a monitoring and review programme that tracks injury trends and worker feedback after roll-out.
Who Should Attend
Ergonomists assessing manual handling and overhead work tasks for mechanical assistance.
Occupational health advisers screening workers before exoskeleton trials.
Safety managers piloting wearable assistive devices in warehousing or construction.
Procurement specialists comparing exoskeleton suppliers and device specifications.
Production supervisors overseeing tasks where workers wear assistive devices.
Manual handling trainers integrating exoskeleton use into safe systems of work.
Course Modules
Select any module to see its sessions and points.
01Understanding Exoskeleton Types and Task Fit
2 sessions · 8 points
Session 1Passive, Powered and Hybrid Exoskeleton Designs
- Distinguish passive exoskeletons using springs or elastic elements from powered exoskeletons with motors and batteries, and hybrid designs combining both.
- Identify back-support, shoulder-support and combined designs and the specific joints and movements each is intended to assist.
- Review manufacturer data on assistive torque or force, weight, and battery duration where relevant, rather than relying on marketing claims alone.
- Assess how device weight and bulk may affect balance, freedom of movement and compatibility with existing personal protective equipment.
Session 2Matching Devices to Manual Handling and Overhead Tasks
- Analyse the manual handling or overhead task, including load weight, frequency, posture and duration, to define the assistance actually required.
- Compare static overhead work, such as installation or welding above shoulder height, against dynamic lifting tasks that need different support profiles.
- Rule out exoskeleton use for tasks requiring frequent bending, twisting or fine motor control where the device may restrict natural movement.
- Prioritise engineering controls, such as lift assists or workstation redesign, ahead of exoskeletons where a task can be eliminated or mechanised instead.
02Assessing Fit, Suitability and Secondary Risk
2 sessions · 8 points
Session 1Screening Workers and Fitting Devices
- Establish a medical screening process to identify contraindications such as cardiovascular conditions, hernias or existing musculoskeletal injuries.
- Fit each device to the individual worker's body dimensions, adjusting straps, pads and support points to avoid pressure points and chafing.
- Train workers on donning, doffing, adjusting and safely removing the device, including emergency release for powered exoskeletons.
- Record informed consent and provide a trial period during which workers can report discomfort without pressure to continue use.
Session 2Identifying Secondary and Emerging Risks
- Assess the risk of balance loss or trip hazards created by device bulk, especially on uneven surfaces, stairs or ladders.
- Identify pinch points, entrapment risks and skin contact hazards from straps, frames and powered joints during use and adjustment.
- Evaluate the risk of muscle deconditioning or over-reliance on the device if workers use it beyond the tasks it was selected for.
- Consider electromagnetic interference, battery safety and charging hazards for powered exoskeletons used in the specific work environment.
03Running a Structured Pilot Trial
2 sessions · 8 points
Session 1Designing the Pilot Protocol and Measures
- Define pilot objectives, duration, participant numbers and comparison tasks before selecting measurement methods.
- Select practical measures such as rating of perceived exertion, task completion time and worker-reported comfort suitable for a workplace pilot.
- Establish baseline measurements without the device before introducing exoskeleton use so improvement can be assessed against a comparable start point.
- Set clear stop criteria, including discomfort thresholds or performance decline, that trigger early withdrawal from the pilot.
Session 2Comparing Devices Against Task Performance
- Compare trial results across candidate devices using consistent tasks, participants and measurement conditions.
- Weigh comfort, ease of donning, range of motion and perceived exertion reduction alongside cost and maintenance requirements.
- Gather structured worker feedback through interviews or short surveys rather than relying on informal impressions alone.
- Document the rationale for the selected device or devices, including tasks where no exoskeleton was found suitable.
04Procurement, Roll-Out and Ongoing Monitoring
2 sessions · 8 points
Session 1Building the Procurement and Roll-Out Plan
- Specify device requirements, including adjustability range, cleaning and maintenance needs, and spare parts availability, in the procurement brief.
- Plan a phased roll-out starting with volunteer users and high-benefit tasks before wider deployment across a site or workforce.
- Update manual handling risk assessments and safe systems of work to reflect exoskeleton use as a control measure, not a replacement for training.
- Assign responsibility for device maintenance, inspection and battery management to a named role within the safety or facilities team.
Session 2Monitoring Outcomes After Deployment
- Track musculoskeletal discomfort reports, near misses and device-related incidents after deployment to detect emerging problems early.
- Review usage rates and worker feedback periodically to identify devices that are underused or abandoned after initial adoption.
- Reassess device suitability whenever task demands, workforce composition or facility layout change significantly.
- Feed monitoring results back into the wider manual handling and musculoskeletal disorder prevention programme.
What the participant receives
4 course modules
A structured syllabus
8 training sessions
across 5 days
32 detailed points
Applied, detailed content
Accredited attendance certificate
On completing the programme
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