Profitability of exoskeletons for working at heights

Repetitive tasks with raised arms, such as overhead assembly, sanding, or industrial painting, are among the most physically demanding. They often cause shoulder pain, significant fatigue, and even chronic injuries. More and more companies like Toyota, Boeing, and IKEA are investing in passive exoskeletons to improve the health and productivity of their employees. Are these tools cost-effective? The answer is clearly yes.

Fewer injuries, fewer stoppages

At Boeing, some teams have recorded zero shoulder injuries after adopting arm-assist vests. Ford has observed up to a 90% reduction in ergonomic issues at overhead stations. IKEA, for its part, has improved operators' posture by 65%, significantly reducing pressure on the spine.

These improvements directly translate into fewer work stoppages, reduced costs related to injuries, and a safer environment for teams.

Less fatigue, more energy

Arm exoskeletons allow for a perceived load reduction of 5 to 8 kg during repetitive tasks. As a result, operators feel up to 55% less fatigued by the end of their shift. Many report being able to finally finish their day with enough energy to enjoy their personal life, a real change in their daily routine.

Direct effects on productivity

Less fatigued, employees work more consistently, take fewer breaks, and maintain their focus longer. Trials in warehousing have shown an average increase of 8% in productivity with the use of passive exoskeletons on certain physical tasks.

A quick return on investment

On the financial side, the purchase of an exoskeleton quickly pays for itself. Preventing a single serious injury can save between $20,000 and $50,000 in direct costs. In some cases, companies have recouped their investment in less than 6 months, with an estimated return on investment of 13 to 1 over five years.

Conclusion

Far from being just a gadget, the passive exoskeleton for overhead work is a concrete, effective, and cost-effective solution for companies. It protects workers, enhances their comfort, reduces injuries, and increases productivity, all at an extremely low cost of use. A humane, useful, and sustainable technology.