This blog was originally published on February 26, 2024, but has been updated as of May 12, 2026.
Like many Minnesota employers, you’d probably like to reduce workers comp costs and employee absenteeism. The best way to do that? 👉 Prevent injuries with proactive workplace health strategies — including implementing the OSHA hierarchy of controls.
OSHA (Occupational Safety and Health Administration) promotes the use of a hierarchy of controls to effectively manage and reduce workplace hazards and risks. The hierarchy of controls is a systematic approach that prioritizes various strategies to address workplace hazards, with the goal of reducing the risk of injury or illness.
The OSHA hierarchy of controls consists of five levels, listed here in order of preference.
Image from cdc.gov.
Elimination
The highest and most effective level of risk reduction and control involves elimination: completely removing the hazard from the workplace.
This means finding ways to redesign processes, tasks, or equipment so that the hazard no longer exists. If a hazard is eliminated, there is no longer a risk to control. Elimination should always be the first choice when possible.
Substitution
When elimination of the hazard is not possible, the next best approach is substitution. This involves replacing the hazardous substance, process, or equipment with a less hazardous alternative.
Substitution can help reduce the risk of injury while maintaining the same level of productivity or functionality.
Note: When choosing a substitute, don’t forget to consider any potential new risks the substitute may add. The goal is to reduce risk — not merely replace it with a different risk.
Engineering Controls
Engineering controls are physical changes to equipment or the workplace environment that reduce employee exposure to the hazard. Engineering controls can be used in cases where elimination or substitution of the hazard is not possible.
Examples of engineering controls include:
- Machine guarding
- Ventilation systems
- Noise enclosures
- Lift assist devices
- Adjustable workstations
- Anti-fatigue flooring
- Safer machinery design
- Ergonomic tool redesign
Engineering controls like these do not rely on employee behavior for their effectiveness.
Administrative Controls
Administrative controls involve implementing policies, procedures, or work practices to reduce exposure to hazards. This includes:
- Scheduling
- Employee training
- Signage
- Job rotation
- Providing personal protective equipment (PPE)
Because they depend on employee compliance, administrative controls are less effective than elimination, substitution, or engineering controls.
Personal Protective Equipment (PPE)
PPE provides a physical barrier between employees and workplace hazards, and includes equipment like hard hats, gloves, and safety glasses.
When it comes to preventing workplace injury, PPE is often the first thing people think of. However, it should be the last line of defense.
While essential in some situations, PPE is the least effective control measure because it does not remove the hazard from its source. OSHA recommends using PPE only when other control measures are not sufficient or possible.
By minimizing or eliminating exposure to hazards, the hierarchy of controls can help reduce lost-time injuries and improve employee productivity, wellness, morale, and retention.
However, it's important to note that the hierarchy of controls is not a one-size-fits-all approach. The selection of control measures should be based on a thorough risk assessment that considers the specific hazards, work environment, and usability of each control method.
Effective hazard control usually involves multiple control measures from different levels of the hierarchy. Additionally, control measures may need to be reviewed and adjusted periodically to ensure ongoing safety in the workplace.
5 Ways Employers Can Apply the OSHA Hierarchy of Controls Today
To give you an idea of what implementing the hierarchy of controls can look like in a workplace, here are five ways to apply them.
1. Evaluate Repetitive Motion Tasks
Repetitive movements are one of the leading causes of workplace musculoskeletal injuries. Employers can apply the hierarchy of controls by identifying tasks that require repeated lifting, reaching, bending, twisting, or gripping, then determining whether those motions can be eliminated, reduced, or redesigned.
For example, you may be able to:
- Automate repetitive processes
- Rotate tasks to reduce overuse injuries
- Use lift-assist devices or conveyor systems
- Redesign workflows to minimize awkward movements
Addressing repetitive motion risks early can help prevent strains, sprains, tendonitis, and other costly workplace injuries before they become recordable claims.
2. Improve Workstation Ergonomics
Poor workstation setup can contribute to neck pain, back injuries, shoulder strain, and fatigue, especially in office, manufacturing, warehouse, and healthcare environments. Engineering controls like this can significantly reduce employee exposure to injury risks.
Employers should evaluate:
- Desk and chair height
- Monitor positioning
- Tool placement
- Standing vs sitting requirements
- Reaching distances
- Flooring surfaces
Simple ergonomic upgrades like adjustable workstations, anti-fatigue mats, ergonomic tools, and proper seating can improve comfort, productivity, and injury prevention.
3. Implement Stretching and Wellness Programs
Stretching programs, wellness initiatives, and movement education can help employees prepare their bodies for the physical demands they face throughout the workday.
Examples include:
- Pre-shift stretching routines
- Ergonomic safety training
- Hydration and fatigue awareness programs
- Wellness coaching
- Injury prevention education
These programs can improve flexibility, circulation, posture, and body awareness, helping reduce soft tissue injuries and employee fatigue over time.
4. Train Supervisors on Early Injury Reporting
One of the most effective administrative controls is creating a culture of early reporting and rapid response. Supervisors should be trained to recognize signs of discomfort, fatigue, or repetitive strain before a minor issue becomes a serious workers compensation claim.
Early intervention strategies include:
- Prompt injury reporting procedures
- Modified duty programs
- Ergonomic evaluations
- Immediate access to occupational health resources
- Encouraging employees to report symptoms early
When supervisors understand how to respond quickly and appropriately, they can help reduce lost time, improve recovery outcomes, and prevent injuries from escalating.
5. Provide Onsite Injury Prevention Services
Bringing injury prevention services (like those ErgoWorks provides) directly into the workplace can help employers proactively manage risk and support employee health.
Onsite services can include:
- Ergonomic assessments
- Stretching programs
- Movement screenings
- Injury prevention education
- Early symptom intervention
- Job demand analysis
These services allow employers to identify workplace hazards in real time and apply OSHA hierarchy of controls principles more effectively. Proactive onsite support can lead to fewer injuries, lower workers comp costs, reduced absenteeism, and improved employee morale.
Prevent Workplace Injuries With Help From ErgoWorks
At ErgoWorks, we offer injury prevention services with an onsite therapist as part of our OnsiteWorks service.
Through weekly or biweekly visits to your workplace, this service helps you recognize and address symptoms before they become an injury that costs you time and money. We have new pricing and scheduling options, with current openings available on Tuesdays and Wednesdays. Bulk pricing plans are available as well.
ErgoWorks injury prevention programs help you reduce risks before injuries occur, creating a safer, healthier, and more productive workplace. Schedule a discovery call today to learn more.