When Terumo Medical Devices in Elkton, Maryland set out to improve ergonomics across its facility at the start of 2025, leadership knew they needed more than training. They needed a sustainable system that would engage employees, build ownership, and create lasting change.

According to the site’s Director of Operations, the goal was straightforward: establish the infrastructure and coaching necessary for employees to become more capable of identifying ergonomic risks and implementing effective solutions.

With that objective in mind, Ergo-ology recommended its Ergonomics Leadership Program, a 12-month mentorship experience designed to develop high-performing ergonomics teams and create a culture of continuous improvement.

Building the Right Team

The program began with the formation of a cross-functional ergonomics team that brought together employees from engineering, continuous improvement, operations, supervision, and frontline production. This diverse perspective ensured that problems could be viewed from multiple angles while strengthening collaboration across departments.

Unlike traditional training programs that deliver a large volume of information all at once, the Ergonomics Leadership Program focuses on gradual, practical development. Each month, the team met virtually for one hour to learn a relevant ergonomics topic, discuss project updates, and receive targeted assignments that provided direction and focus for the next 30 days.

At every meeting, progress was reviewed, new opportunities were added to a tracking system, and the team continued building upon the foundational skills necessary to become effective ergonomics leaders.

More Than Training: Mentorship Matters

As with any newly formed team, technical knowledge alone wasn’t enough.

Success required coaching in three critical areas:

• Psychological growth and confidence
• Operational problem-solving
• Vision and purpose

Drawing upon decades of mentorship experience, the Ergo-ology team worked closely with participants to clarify roles and responsibilities, strengthen collaboration, and cultivate intrinsic motivation.

One of the most important lessons for team members was understanding that they were part of something larger than themselves. Every participant brought unique strengths to the table, and every contribution played a critical role in improving both employee well-being and operational performance.

When people understand the impact of their efforts, engagement naturally follows. The result was a team that didn’t simply identify problems, they became invested in solving them.

Results that Speak for Themselves

Over the course of the 12-month program, the team achieved remarkable results:

• Learned and applied 10 ergonomics awareness topics
• Identified 68 ergonomics improvement opportunities
• Assessed 52 workstations
• Implemented 32 ergonomic controls

The team’s efforts generated momentum that extended far beyond the program itself.

Approximately eight months (7/23/2026) after completing the mentorship experience, Terumo reported that injury rates had continued trending downward, achieving a 32% reduction. In addition, 27 of the improved workstations were experiencing measurable gains in productivity and quality.

These outcomes reinforced an important principle: ergonomics is not merely a safety initiative. When designed and implemented effectively, ergonomics becomes a business improvement strategy that benefits employees, operations, and organizational performance simultaneously.

The Proof Is in the Progress

As the saying goes, the proof is in the pudding. The measurable reductions in injuries, along with improvements in productivity and quality, demonstrated that empowering employees to lead ergonomic improvements delivers real and lasting results.

Because of the success achieved by the original eight-member team, Terumo Medical Devices made the decision to expand the concept throughout the facility. What began as a single ergonomics leadership team has now grown into four additional teams representing other departments, creating a broader network of employee-driven problem solvers and champions for workplace improvement.

Creating Sustainable Change

Terumo’s journey illustrates what can happen when organizations move beyond one-time training and invest in coaching, mentorship, and employee ownership.

By building internal capability, creating structure, and empowering employees with the tools to identify and solve problems, the company has established a foundation for sustainable ergonomic excellence.

The most successful ergonomics programs are not built by consultants or managers alone. They are built by engaged employees who are given the opportunity, guidance, and confidence to lead.

At Terumo Medical Devices, that investment is paying dividends in safety, quality, productivity, and culture, proving that when people are empowered to improve their workplace, extraordinary results can follow.