Verve Motion Blog

Results from the Field: The Impact of Verve Motion’s SafeLift Exosuits

9 Minute Read

In this post, we review the results from several studies carried out by our customers across multiple industries and SafeLift™ use cases.

Background

Based on a decade of research at Harvard University’s Biodesign Laboratory funded by the military, and backed by over $40 million in venture funding, Verve Motion has commercialized a groundbreaking workplace safety and productivity solution: the SafeLift™ exosuit.

The exosuit is a soft, lightweight wearable robot designed to alleviate up to 40% of the strain from workers during lifting operations. Worn like a backpack, it works in tandem with the user's muscles, providing essential support to reduce the risk of injuries, particularly to the lower back and hips. This suit is notable for its quick setup and minimal training requirements, making it a practical solution for large-scale deployment.

Deployment Across Industries

To date, the SafeLift™ exosuit has helped workers across scores of sites lift over 500 million pounds.

Designed for rapid setup and high performance, the suit is being deployed across multiple sectors including food and beverage, third-party logistics, and manufacturing – all industries involving repetitive lifting tasks where reducing injuries and enhancing worker efficiency are crucial.

Measurable Impact: Results from the Field

What SafeLift customers have found are three categories of benefits:

First, there’s a major reduction in injuries. The results vary from site to site based on a number of factors, but our customers have consistently reported significant reductions in injuries – by up to 85%.

Second, because the suits literally do part of the lifting work, associates exert less effort throughout the day, become less fatigued as the day progresses, and often exhibit an increase in productivity (typically 2-8%).

And finally, the associates report overwhelmingly positive sentiment regarding the SafeLift suits, and organizations measuring things like employee engagement and satisfaction report meaningful improvements.

The efficacy of the SafeLift™ exosuit is best illustrated through real-world case studies – several of which are summarized below.

These studies employed rigorous measurement methods to quantify the benefits of SafeLift™ deployments, including within-subject analyses (pre- and post-deployment comparisons) and within-group comparisons (suit versus non-suit users). Key metrics assessed included:

  • Productivity: Items selected per hour, pounds moved per hour, and job accuracy.
  • Injury Rates: Incidence and severity of back and hip injuries, average claim costs, and days lost or restricted.
  • Retention: Employment duration and completion rates of new associates.

 

Case Study 1: Leading Grocery Chain Sees 85% Reduction in Injuries

In a 12-month study conducted with a leading grocery chain, 47 employees used the SafeLift exosuit, while 500 employees served as a baseline. The results were striking, showing an 85% reduction in lower back and hip injuries. The injury rate dropped from 70 injuries per 500 employees to just 1 injury per 47 employees. Additionally, over 93% of the exosuit users stated that they would recommend the suit to their coworkers.

Case Study 2: Grocery Retailer Reduces Injuries among New Associates

A study aimed at improving safety for new associates was conducted over 12 months. At this site, new associates had a particularly high injury rate. SafeLift was deployed to reduce the injury rates for new associates.

As a baseline, the study compared 300 experienced associates (600,000 hours worked over the course of the year) with 40 new associates wearing SafeLift exosuit (79,000 hours over the course of the year). The results showed 79% less injuries among new associates. Furthermore, 95% of the new employees expressed satisfaction with the suit

Case Study 3: Leading Grocery Chain Improves Productivity by Reducing Fatigue

A leading grocery chain set out to study the impact of the SafeLift exosuits. The hypothesis being tested was that by reducing fatigue, SafeLift helps with associate productivity (as measured by cases picked per day). The performance of 21 experienced associates was studied over the course of 26 weeks (consisting of a 15-week baseline, and an 11-week period of wearing the SafeLift exosuits).

During the 11-week period of wearing the exosuit, workers exhibited a 7.7% productivity improvement. The study also noted a 40% smaller variation in productivity across the associates, relative to the productivity distribution prior to the suits.

Between injury reductions and productivity improvements, the company estimates a 5-month payback on SafeLift suits.

Case Study 4: Regional Logistics Leader Reduces Injuries

A regional logistics leader deployed 25 SafeLift suits in a 9-month study. During this period, the suits helped workers lift over 14 million pounds with no injuries reported.

96% of the study participants reported improved posture, and 90% indicated they would recommend the exosuit to colleagues.

Case Study 5: Leading International Grocery Distribution Chain Reduces Unsafe Movements by 36%

The SafeLift solution not only aids in lifting but also reduces injuries by promoting safer movements. The suit delivers assistive forces and offers personalized coaching reports for each associate. These reports provide actionable insights by highlighting safety practices and pinpointing areas for improvement.

The suit utilizes inertial measurement units (IMUs) embedded in the exosuit to monitor and record various movements that are linked to back injuries, such as excessive torso bending, twisting, side bending, and prolonged bending.

A 5-month ergonomic study involving 50 SafeLift users – each lifting 2,000/day on average – looked at the impact of the SafeLift suit on reducing unsafe movements during lifting.

The study showed a significant decrease in the number of unsafe lifts from 760 to 485 per day, eliminating 275 unsafe lifts daily per worker (i.e., eliminating 70,000 unsafe lifts per work on an annual basis!).

Case Study 6: Leading Grocery Chain Reduces Injuries by 61%

In a 12 month study at one of their largest distribution centers, a deployment of 120 SafeLift exosuits lead to a 61% reduction in lower back and hip injuries. To date the SafeLift exosuits at this facility have helped lift over 50 million pounds. 

And with the lighter lift, workers reported they were able to execute tasks with less effort, leading to increased throughput and efficiency on the warehouse floor.

Case Study 7: North American Retail Leader Improves Selector Productivity

Over a 21-month study with a leading North American retail chain, 40 SafeLift suits were deployed. The study reported zero injuries and a 1.5% productivity improvement, leading to a 5.8-month payback period for the exosuits.

Case Study 8: Customer ROI Analysis

A leading grocery retailer conducted an ROI analysis after a 3-month initial deployment of 25 suits, projecting the savings for a full deployment of 250 suits.

The analysis projected annual savings of $880,000 from injury reduction, $280,000 from turnover reduction, and $660,000 from productivity gains – resulting in a 250% ROI with a 5-month payback period.

SafeLift Helps Drive Positive Sentiment among Workers

Feedback from SafeLift™ users and customers has been overwhelmingly positive, with survey results indicate high levels of satisfaction and significant reductions in fatigue and soreness among workers, and a substantial return on investment for exosuit customers.

User satisfaction surveys indicate high levels of acceptance and effectiveness:

  • 97% of users felt assisted by the exosuit.
  • 79% reported less fatigue after use.
  • 87% experienced reduced back muscle soreness.
  • 83% noted improved lifting posture.
  • 98% would recommend the exosuit to a coworker.
  • 88% found the benefits outweigh any inconveniences.
  • 95% were overall satisfied with the exosuit.
  • 82% found it comfortable to wear and use.

Conclusion

Verve Motion’s SafeLift™ exosuit is revolutionizing workplace safety and efficiency. By significantly reducing injury rates and improving productivity and worker satisfaction, it showcases the power of wearable robotics in enhancing human capabilities. As more industries adopt this technology, the positive impacts on worker health, operational efficiency, and overall business performance will continue to grow.

To explore how the SafeLift™ exosuit can benefit your team, book an on-site live demo and operational assessment today.