Ergonomics Meets Human Factors: Building Safer, Smarter Workplaces with Dr. Era Poddar
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In this week’s episode of The Safety Guru, we’re joined by Dr. Era Poddar, who shares her extensive expertise in ergonomics and human factors to explore what these principles are, why they matter, and how organizations can proactively integrate them into workplace design to transform safety outcomes, boost productivity, and build safer, smarter workplaces. She discusses the wide-ranging benefits of integrating these principles, including better decision-making, reduced cognitive load for employees, fewer errors, a lower risk of serious injuries and fatalities, and measurable returns on investment (ROI) through improvements in quality, productivity, and overall safety performance. This insightful discussion also highlights how leaders can champion ergonomic improvements, leverage emerging technologies that are reshaping workplace design, and foster a culture of continuous learning and improvement. Tune in to discover how ergonomics and human factors work together to build safer, healthier, and more productive organizations. Don’t miss this episode!
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Real leaders leave a legacy. They capture the hearts and minds of their teams. Their origin story puts the safety and well-being of their people first. Great companies ubiquitously have safe yet productive operations. For those companies, safety is an investment, not a cost for the C-suite. It’s a real topic of daily focus. This is The Safety Guru with your host, Eric Michrowski, a globally recognized ops and safety guru, public speaker, and author. Are you ready to leave a safety legacy? Your legacy success story begins now.
Hi and welcome to The Safety Guru. Today, I’m very excited to have with me Dr. Era Poddar. She has a PhD in industrial ergonomics, an MBA from UBC, does a lot of consulting work in the ergonomic space, and is also an adjunct professor at the University of British Columbia. Era, so happy to have you with me today on the show.
Thank you, Eric, for the introduction. And I would like to just— mini-MBA.
Mini MBA?
Yeah, it’s not the full MBA at length, but I will reflect on that a little bit. Okay. Why I mentioned that. Yeah, thank you. I’m really glad to be talking to you today.
Absolutely. So, tell me a little bit about how you got started in ergonomics and the passion you’ve gotten for safety and ergo.
Right, it’s a very interesting question, and I, I have been asked about this for so many times. I remember talking to in one of the platforms in my previous employer, some people were talking about different epiphany happened to them, and that’s what they came. To be very honest, I never had such, such incidents, or I would say positive incidents, but what I had in the— I first, to, to be very honest, I learned about the subject when I went to the university to do my master’s program. And so, it’s a human physiology master’s from University of Calcutta. They had a specialization in ergonomics and human factors. So that’s where first I came across the subject. No one knew about this. I was pretty intrigued about the subject because it has direct implications on human life. Like, of course, industry to design and everything. So eventually, I got to love the subject, and I became passionate about it.
And it’s taking you all around the world. And so that gives you fairly unique perspectives as well in terms of how you’ve applied ergonomics in that space. Maybe let’s start with what is ergonomics and why is it so important?
Right. I should go back to a little bit because I had to also touch base on things which, which intrigued me to be part of this subject. One was like, I started my career in a design project, a mining scenario, and I thought that would be pretty interesting for the audience. So, this project ran for 1.5 years, and then we, we redeveloped or redesigned, uh, certain equipment’s, over 10 of them. And during that time, I realized this subject has a different application and we need to pursue more. That’s where I started doing PhD and all that, all the things. Uh, but as you know, life happens, things change, and I, I started my career in a university setting teaching after completing, uh, my PhD. So, while teaching, there are different design applications from physical product design to interaction design and all that. Stuff. So then, as usual, things change, uh, and I followed my husband to Middle East, and that’s where, uh, it’s a different, uh, scenario of ergonomics kind of came into my understanding because it’s a business side of it. That’s when I started my business because there was less scope of applying in the education domain.
Sure.
And before that, I lived a little, uh, time teaching in Nepal, one of the universities, medical school. So, all these things and, uh, kind of intrigued me to apply different domains of this area as well as leaving my comfort zone, I guess. So, in Dubai, we kind of, uh, what we did was, as I said, there’s less education apply— like application or courses. However, there was a scope, uh, to represent companies who had multiple offices across Middle East to help them in their ergonomics initiatives. So, you could call it a beginning of a mini-MBA for me, hands-on practice, and which I wouldn’t have done otherwise if I wouldn’t be leaving my secured career path. And that’s where it’s a different approach which, which is taken from there. And then onwards, I lived in the US and practiced, and then it came back to Canada at one point. So, through all this journey, which why I, I wanted to mention that I— it gathered to me, one is I understood the local practices, standards, and all that.
Sure.
It also did an interesting thing to me. I became more and more open and like it grew empathy to me more. And that is one of the key factors we practitioners in ergonomics do. And it’s really one of the key important factors to be successful in this field. Right. And coming back to your question, what is human factors and ergonomics? Is essentially reducing the mismatch between product or system and the user. So, in one word, however, there are several, um, definitions you could find. That is, it’s a science of work design, science of workplace design, and so on and so forth. But we always emphasize on one important aspect aspects of ergonomics and human factors, two different words. Yeah, coined together, they actually mean the same according to International Ergonomic Association. Uh, the overall— I mean, uh, the definition is, is like human factors or ergonomics is concerned with the understanding of interactions among humans and other elements of a and this profession applies theory, principle, data, and methods to design and optimize human well-being and overall system performance. So, we always focus into the system level, uh, changes so that it affects in an effective way for long term.
So yeah, in one word, it helps, uh, I think, reduce any mismatch between any system and product. And improve productivity.
And so why is it so important for businesses to look at that combination of ergonomics and human factors? And what’s the ROI that comes from it?
It is a very interesting question. And we still, I mean, it’s proven, understood that it’s a business-friendly concept.
Sure.
Why? As I said, it reduces mismatch in very different ways. From building design to the product design, even for software design. So, there is a coin word called usability. That’s actually how you reduce the mismatch between human and the software or any interface design. So, over the years, it has been shown to be kind of helpful for the business. And why it is helpful? It reduces error, less time, and sometimes the processes are improved in, like we call them, ineffective time. How you reduce them? All this together, as well as a different reachability and use— usability, or ease of usage of any, any such product. Or given— I will just give you some examples.
Yeah, that would be good.
Yeah. Like for, uh, suppose a company who has a production line who produces certain products. Now if the workstations are higher compared to who are operating and there are a lot of reaches, like you move your hands pretty quickly and there’s long reaches. Now if we do it once or twice, that’s fine, right? And if you do it throughout 8-hour shift, sometime industry have 12-hour shift. To. Sure. So, these are the different aspects. One is size-wise, one, one is process-wise. And suppose you have kept certain products or so stored certain products in a different section. Now the employee has to go bring them. So, there are different touch points and different level of postures which is happening, which could have avoided with a better design.
Sure.
When the industry is built or when the workstation— yes, when the workstation was designed. So that’s where if we incorporate these issues, like how this whole process works, where, where people has to interact, and who will be the person who will be interacting. It is a range of people, not every— like, for even given, uh, different genders, there are sizes. And suppose, giving example, 95% percentile stature, people may not be having 95th percentile hand length or arm length, right?
Right.
So, all these challenges kind of available, or it is there within any workstation workplace setup. So, the more we kind of accommodate these requirements since the beginning, you definitely kind of benefit. And end of the day, product quality also improved. So, this whole span of activities, if we consider it effectively, we will save on time, we will reduce injuries, and the injuries will be less fatal, as well as there will be less error. As a result, you will get a product which is quality-wise better and more product. So, it’s an overall win-win for both employees and the employers in a way. I hope I understood.
No, no, absolutely. Yeah. So, and it’s something, as you talked about, it can mean how I design a plant for how the workers are going to work in. But I could also retroactively drive some improvements. So, there is less movement that’s unnecessary, less lifting, bending, stretching, overreach occurring throughout the day.
Also, less decision-making.
Sure.
Because more and more workplaces becoming automated.
Yeah.
And people are even in regular manufacturing settings; we see employees has to interact with machines where they have to put input and given that the cycle number and what is the output number and all that. So, these— all these interactions are happening at like simultaneously.
Sure.
So, there are cognitive demand as well as physical demand. I, I just gave you a very simple industrial scenario. So, there are complex scenarios like pilots interacting with machines, or we are driving a car. There are so many distractions these days, from external to internal to phone and displays and stuff. So yeah, it makes more sense to incorporate through the design at the beginning. However, it could be applied in every stage.
Sure. Yeah, to drive improvements, to improve the work practices, but also the cognitive load that you mentioned before in terms of the decision-making. I like your example of the car as well. So very, very beneficial. As you said, there’s a The ROI is really because it’s helping, one, the workers, but it’s also helping productivity directly. If you have less distractions, you have less complexity in your decision-making and less movement to complete the task. Is that fair?
It is fair. And I should also add where it is, most of the time, the ergonomics or human factors concepts are applied towards later phase, like when you have an injury, right? And this is not that proactive, more reactive approach. Unfortunately, in— especially not even only in Canada, I have seen in the US or even in the Middle East, that’s where we are called as a practitioner. So, when everything is all set, you have a process set, you have a design set, and there are also different teams working together, not including one of, like, human factors or ergonomics professionals within. So, what it does is there’s always a gap remaining. So, end of the day, which we see, there is an incident, and most popular incident which relates to ergonomics, human factors, that’s musculoskeletal injuries.
Yep.
And that’s where people think that’s what ergonomics is, which is not at all, uh, right directions. But that’s where most of the time we are called in. So as there also huge number of dollars are lost every year, if we see the recent statistics even through WorkSafe BC locally. It’s over $2 billion of cost.
Sure.
And over the year, like recent years. So that is something has to be definitely seen as one of the ROI where we could control this cost.
And ideally done proactively, right? So, as you mentioned in the plant design, or even at a later stage to drive improvement.
Yeah, true. Unfortunately, that is not always done that way.
Yeah, unfortunately not. Yes. Yeah, unfortunately, sometimes you need an event to realize it wasn’t designed the right way. So, one of the things I know when we first connected that you touched on, which I thought was very interesting, is around changing workplaces. And there’s a lot of changes in the current workplace. How does that impact the space of ergonomics and human factors.
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Few things we have to understand. Since World War II, when the subject evolved, many organizing factors, there’s very less understanding across other disciplines about the breadth an application of the subject. So, when, uh, the workplace changes considerations came into play, especially in Canada with the Inclusive Act and all that thing, uh, the concept remained pretty old. Like, it’s not that new, right? Uh, so the changing workplace has been— we see, just giving you an example, if we visit, even you come to any public place or any workplace, you will see different variations of populations coming from different cultures, background. So how does it affect the workplaces? Uh, one is size, like your anthropometric measurements. You have a different language spoken throughout like when growing up. So, you are learning a different language, you are getting instructions through different languages. As the same— at the same time, we have different, uh, equipment’s incorporated into the workplace, more like recent AI. And over the years, we have seen a lot of more automation happen. So, employees are interacting with various different as I mentioned earlier as well, the physical, like manual material handling to giving input to the machine to do a proper setup speed.
Sure. And the production. At the same time, you are getting information through your handle devices.
Yep.
And you are also interacting with some of those displays. And there’s a workplace changes happen through the age. We have older work curse, who has limited ability to interact with digital devices, right? So, these are a complex scenario where you have different, different genders, you have different background, you have different language, culturally different thinking. We don’t have enough time to talk about that stereotype things, but it is there. We think differently, we perform, understand differently. So, these vast and different sizes, as I mentioned, we incorporate this whole group of population within a particular workplace. Right. So, definitely there will be repercussion on that. Yeah. Unless it is really designed well or it is accommodating all this requirement. And at the same time, you have differently abled people who have limitation like moving or different level of cognitive abilities. So, there are so many different challenges within that place. So, when we say the accessible or universal design concept, so we, we talk about all of these people is welcome in that workplace or any space, and they can easily interact with all these different things. And how we make those things user-friendly for them. So that’s when we talk about different level of accessibility or universal design.
Which really means a lot more flexibility in terms of how you would interface with equipment, the technology, potentially very different sitting position, if in that scenario, you’re talking about, where there’s flexibility of adjusting depending on what’s right for that particular individual.
Yeah, I can provide you another simple example. Suppose you are accessing, uh, like an ATM machine, right? Right. So now, for people like you and me, I will go walk, park the car, go walk and access. It’s not a big deal. We know these are bigger buttons and everything. Now consider this person who cannot move, who is on the wheelchair.
Yeah.
Now there are different level of accessibility they need. So, he has to access the building first. There has to be certain ramp where they can access. And then there has to be certain reach so that they can see it, still see it, and interact with the machine, right? Not only physical buttons, but there are also digital buttons.
Sure.
So, then there are all these requirements. So, you have a person who will operate this machine standing, there’s a person who may come on the wheelchair, there’s a person who may come in differently, other way of different, and there is person who cannot see. And also, the language-wise, so people may read English well, some may not, some may come from suppose Mandarin They speak Mandarin, reads Mandarin or Japanese.
Sure.
So, consider a world where all these people live together and interact with the machine. So that’s where the usable or universal design or accessibility come.
And bringing that to workplaces as well, because the same example, it’s how do I design a work environment, whatever that work environment might be, to have that flexibility in terms of interaction.
That’s right.
Excellent. And I know one of the themes we also touched on is around now that we’re hearing more and more about exoskeletons. How does that play into these human factors and ergonomics space?
That is another interesting area of time. Anytime we talk to colleagues, they come up with this question. So, I was recently listening to one of the webinars done by— I don’t remember the organization, but the person who was presenting, Dr. Christopher Reed from Boeing, he was reflecting on many such research and applied within the Boeing scenario. I will refer some of her— some of his topics. So, exoskeleton is, of course, related to ergonomics. It’s not like insects and others. So, it’s an external structure which helps us to support while working.
Sure.
So, we call them industrial exoskeleton. And there are different types. Some are automated. I mean, they are more advanced these days. But essentially, it is built to support while working.
Right, sure.
So, few, a few different types. I’m very broadly, I’m touching this. One is made for postural assist system, like when someone is working within an environment or very concise space where you cannot do any engineering changes, where you cannot implement those changes. So that person has to work in a certain position, suppose electrician, in that space. You cannot bring in any other equipment. So continuous working within that space and having those shoulder and arm muscles in the, like, over above shoulder level. So that’s when this type of exoskeleton helps. Like, it’s a postural support where hands and shoulders and— sure, other, other part is supported. There is other type of where you have full body support, like especially doing manual material handling where any other engineering changes or equipment could be provided in such certain scenario. It seems that quite a few other companies, including Boeing, is using them while making the airplanes, not— I mean, after it is done, so before that part. So since employees are using them, I had also interacted with few local clients Sometimes, uh, some of the workers like it, some don’t.
Of course.
So, some of them— I, I was amazed to hear this— the— my contact person who was saying that 2 or 3 of them didn’t like it, so they never would wear them.
Sure.
So, there are 1 or 2, it happened that they wouldn’t open it. Without that, they cannot perform. So, there are different varied level of acceptance. Sure, there’s definitely different types of acceptance level as well as, uh, I mean, the type of work people does. Depending on that, this is effective. So, it’s always the first thing we as a professional suggest. If there is option, engineering changes is better options. In any day. However, there is no, I mean, opening to incorporate such changes, then explore this. Still, there’s a lot to— yeah, there is a lot of research has to go in. It’s still developing.
Yeah, absolutely. I think for me, the first example I saw of this was, I’m going to say it’s almost a decade ago, and it was in Japan with baggage handlers, and it was around how do we reduce the lifting and switching that’s happening when they’re moving bags, which sounded very interesting if you think about the repetitive motions and the— you don’t even know how heavy a particular bag is going to be, which adds a lot more risk as well to that equation.
Yeah, you’re right. And also, I remember mentioning I think 6, 7 years back, uh, still the COVID at the beginning of COVID or before that, there were, uh, we ordered some furniture’s and people came to deliver. Some of the company who was contracted to do that, so the employees, their employees were using those exoskeletons to move those furniture’s. Yeah, so I have seen, it’s interesting, few companies adopted them pretty well. And then sometimes, as I said, it’s, yeah, not always accepted.
And as you talk about change, I think one of the things that makes good sense to transition to is what’s the role of a leader in driving that change, right? So, they can— we talked about your role coming in and assessing, but how can a leader support change?
It’s a Very important and interesting topic, and that’s one of my other passion area these days— how to incorporate human factors ergonomic concept within the strategy, right? So, we all know this concept is old enough. However, it’s less accepted amongst the senior leadership.
Sure.
One main reason is the language we speak. So, language has to be such so it is acceptable to the senior leadership. And senior leadership, one and important part which I realized over the years is, of course, they have to be trained in certain aspects. So, we as a professional has to be able to speak that language which caters to that group. At the same time, leadership has to be a little bit open towards these new concepts coming in, right, which is beyond the conventional, okay, they have— there are standards, engineering standards, and we— sure, we have it, then it is all done. It is not always the case because at the end of the day, users are human, right, right. And or whoever is using it, they are the one who is manipulating with the system.
Right.
So, the leadership’s main, I think, the initiative would be understanding, like keeping a little open mind, one. Second is putting a human factor economics concept as a strategy goal, which is actually part of their business decisions. Then if you have a budget, allocated already, then it’s much easier to implement at the design stage than at the level when an injury already happened.
It really touches the whole space of safety by design, even in terms of if you, if you do things right at the front end, and you’re putting in the time and the effort, you’ll be much better off later.
Exactly. And also, we always say this, you have as a company, every company has their standard operating procedure or SOPs. So, it is always smart to align the programs, including safety, ergonomics, and other programs, to that, right? It’s, it’s much— it makes a lot more sense. And if you remember, I touched upon briefly on a certain point that we have various departments within a company. Unfortunately, some of them, they don’t always interact, or there’s less, less scope, or whatever may be the reason, that interaction is very important. And leadership can bring in that interaction so that same things are simultaneously done but not applied effectively. I have seen that in my practice. That quality team had come up with an idea which is not fully applicable because of the other challenges, However, there was another department have developed a newer idea and applying them within the team which others didn’t know. So again, the communication, communication, and allowing this communication to happen free flowing among different departments without a bias. So that is another leadership role I, I think would be very helpful in such initiatives.
Sure, absolutely. And so, if somebody wants to get in touch with you, what’s the best way to do so? And maybe share a little bit about the type of work that you do to help organizations in this space.
Right. So best way to reach me through LinkedIn. Also, we have our website, www.argoera.com. You can and definitely click to that website and see our services.
Yep.
We do offer different types of services. We do offer the program support where the corporations can— an ergonomist like us or others can work together to come up with a plan or aligning their SOPs, which is more long-term. And I think we focus more into that. However, as I— excuse me— as I said, there are a lot more focus into risk assessment or management. So that’s where a lot of business come through that area. So, we do, of course, cover that risk assessment. It could be your industrial risk assessment to corporate. At the same time, we also do worker compensation. Kind of support. I mean, you do need that kind of risk assessment as well, and all, uh, different types of workshops, being it the executive workshops to strategy level workshops, and also participatory ergonomics.
Makes sense. Excellent. So, Era, thank you so much for joining me today. Appreciate your time.
Thank you so much.
Thank you for listening to The Safety Guru on C-suite Radio. Leave a legacy. Distinguish yourself from the past. Grow your success. Capture the hearts and minds of your teams. Elevate your safety. Like every successful athlete, top leaders continuously invest in their safety leadership with an expert coach to boost safety performance. Begin your journey at execsafetycoach.com. Come back in two weeks for the next episode with your host, Eric Michrowski. This podcast is powered by Propulo Consulting.
ABOUT THE GUEST
Dr. Era Poddar is a Canadian Certified Professional Ergonomist (CCPE) and safety specialist, with broad international experience across North America, the Middle East, and Asia. Her expertise covers industry, academia, corporate, and government sectors. She holds a Ph.D. in Industrial Ergonomics, a NEBOSH International General Certificate in Occupational Health and Safety (practical applications), and a mini-executive MBA from the Sauder School of Business, UBC.
With more than twenty years in consulting, coaching, training, and research related to ergonomics, human factors, workplace accommodation, and safety, Dr. Poddar helps organizations meet goals in health and safety, ergonomics, and MSI control. She currently sits on the Board of Directors for the Canadian College for the Certification of Professional Ergonomists (CCCPE) and actively contributes to the International Ergonomics Association (IEA) Health and Safety Technical Committee, where she leads a group advising on ISO 45001: Guidelines for Ergonomic Processes. Additionally, she is part of the Canadian Mirror Committee (CMC) to the ISO Ergonomics TC 159.
Era is the founder director of Ergoera Services Inc. (https://ergoera.com), which provides customized ergonomics and occupational health and safety services and training. She also serves as an Adjunct Professor at the University of British Columbia, guiding master’s students and professionals in industrial ergonomics, injury prevention, design ergonomics, human-centered design, and user research.
Known as an innovative entrepreneur, leader, and public speaker, Era balances her roles as consultant, educator, researcher, and mentor. She has successfully managed multicultural teams globally, including in North America, Asia, the Middle East, and India. Her work involves leading excellence initiatives, promoting accessibility and universal design, developing safety and ergonomics strategies, and implementing quality improvement programs. Throughout her career, Era has spearheaded ergonomics programs, risk assessments, participatory projects, gap analyses, and process improvements in sectors like manufacturing, mining, food processing, government, corporate environments, and healthcare. Her evidence-based, user-centered approach supports healthier, safer, more functional, and productive workplaces, reflecting her commitment to “Design for All.”
For more information: https://ergoera.com/
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