Man vs. Machine: Tackling Labor Shortages and Workforce Change with Automation and Ergonomics
Man vs. Machine: Tackling Labor Shortages and Workforce Change with Automation and Ergonomics
Executive Summary
Labor shortages, rising injury claims, and shifting workforce demographics are forcing food and beverage manufacturers to redesign the way work gets done. This white paper explores how automation, ergonomic design, and digital augmentation can address these pressures—reducing injury rates, improving retention, and maintaining productivity in a labor-constrained environment. From cobots to smart material handling, we show how “man and machine” together can outperform either one alone.
1. The Workforce Challenge Is Here to Stay
Labor issues are now structural, not cyclical.
Manufacturers across the F&B sector are facing:
- High turnover rates in repetitive and physically demanding roles
- Injury claims and lost time due to ergonomic strain
- An aging workforce less suited to heavy lifting and repetitive motion
- Younger workers seeking technology-enabled, not labor-intensive roles
2. Why Traditional Labor Strategies Are Failing
Throwing more people at the problem no longer works.
Wages have risen, but retention hasn’t improved. Training is expensive. Safety incidents remain high.
Top issues include:
- Repetitive strain injuries from case packing, stacking, and sorting
- High-cost workers doing low-value tasks
- Growing complexity from SKU proliferation overwhelming manual systems
3. Automation as a Workforce Multiplier, Not a Replacement
Automation isn’t just about reducing headcount—it’s about making the existing workforce more capable, safer, and less stressed.
Key areas for automation success:
- Collaborative robotics (cobots): Perfect for pick-and-place, light palletizing, and tray handling
- Vision-guided QC systems: Reduce mental strain and decision fatigue
- AI-based SOP capture: Help new operators learn faster, with fewer errors
- Automated changeovers: Reduce manual adjustments and injuries
Insight: Many cobots now deploy in under 8 weeks and pay back in 12–18 months—without fencing or massive redesign.
4. Ergonomics: The Silent Cost Driver
Ergonomic injuries are among the most expensive—and most preventable—claims in manufacturing.
Contributing factors:
- Poorly designed workstations
- Overhead reaching, bending, twisting
- Manual handling of bulky WIP or packaging
- Inconsistent cycle times causing operator fatigue
Solutions include:
- Lift-assist devices and automated carts
- Adjustable workstations
- Smaller, lighter case configurations
- Smart sensors that alert to unsafe repetitive motions
5. Case Snapshot: Plant Cuts Injury Claims by 70% with Ergonomic Automation
A Midwest snack food facility faced high turnover and rising safety costs at their hand- packing stations.
With InnoFlex, they implemented:
- 2 cobots for packing into club-size cases
- Lift-assist for incoming product totes
- AI-based inspection system to reduce manual checks
Results:
- 70% reduction in OSHA reportables
- $136K/year saved in injury-related costs
- Improved retention and employee satisfaction
6. Man + Machine = Sustainable Productivity
The most future-ready operations blend people and machines, playing to each strength:
- Humans: Flexibility, problem-solving, fine motor skills
- Machines: Repetition, consistency, safety, and uptime
Smart automation supports—not replaces—the operator. This partnership reduces burnout, risk, and turnover while maintaining output.
7. Conclusion: Design for People, Powered by Machines
In a world where labor is scarce and injury claims are rising, operational leaders must evolve.
It’s time to:
- Identify high-strain, low-value manual tasks
- Deploy smart automation to support—not replace—your workforce
- Invest in ergonomics as a bottom-line improvement strategy
Let’s build a safer, smarter production environment— together.
