Ford's EksoVest: How the Auto Giant Cut Workplace Injuries by 83%
Case Study | 2026-06-30
📖 The Case: Ford Motor Company partnered with Ekso Bionics to deploy upper-body exoskeletons across 15 plants in 7 countries. The result: 83% fewer workplace incidents for workers performing overhead assembly tasks — and a blueprint for industrial exoskeleton adoption at scale.
The Challenge: 4,600 Reaches, 1 Million Times a Year
Imagine lifting a bag of flour or a watermelon over your head 4,600 times a day. That was the reality for Ford assembly workers installing underbody components — reaching overhead with power tools to secure bolts and braces, standing beneath vehicles on the assembly line. Over a year, that is approximately one million overhead repetitions per worker.
These repetitive motions placed extreme strain on the shoulders, deltoids, and rotator cuff muscles. According to the National Library of Medicine, a torn rotator cuff costs an average of $26,000 and takes seven months to rehabilitate. Ford recognized that preventing even a single shoulder injury would more than justify the investment in exoskeleton technology.
The Intervention: EksoVest
Ford piloted the EksoVest (from Ekso Bionics) at two Michigan plants — Michigan Assembly Plant in Wayne and Flat Rock Assembly Plant in Flat Rock. The device is a passive (non-powered) upper-body exoskeleton that provides 5 to 15 pounds of lift assistance per arm during overhead tasks. It uses a system of hinges and non-electrical actuators to reduce fatigue in the deltoids and rotator muscles, with no batteries, no cables, and no maintenance beyond cleaning.
Key specifications: the EksoVest weighs under 10 pounds, fits workers from 5 feet 2 inches to 6 feet 4 inches tall, and lasts 5-7 million cycles (2-3 years of daily use). At approximately $100/month when amortized over its lifespan, the economics were compelling.
The Results: Measurable Impact
The two-year pilot delivered remarkable outcomes:
- 83% reduction in workplace incidents among EksoVest users
- 75% reduction in total lost-time incidents across Ford's global facilities since 2005
- 900+ hours of worker validation per participant — workers helped refine and improve the design
- Global rollout confirmed: 15 plants across 7 countries (US, Germany, UK, Spain, France, Turkey, China)
Worker feedback was overwhelmingly positive. "I don't want the EksoVest to ever leave," said Nick Gotts, an original operator at Flat Rock Assembly. "Any job that's overhead, I wouldn't work without it." Paul Collins, a line engineer, reported that chronic back, neck, and shoulder pain ceased, allowing him to return home with enough energy to play with his grandchildren.
NRR Analysis: What This Case Teaches Us
The Ford EksoVest deployment is instructive for any organization considering an exoskeleton program. First, it demonstrates that passive exoskeletons deliver real ROI — no batteries, no complexity, just mechanical assistance that works. Second, the worker-led validation process (900+ hours per participant) was critical to adoption; workers who help design the solution become its strongest advocates. Third, the economics are undeniable: preventing one shoulder injury pays for the device several times over.
For safety leaders in manufacturing, logistics, and construction, the Ford case provides a tested template: start with a focused pilot in the highest-risk tasks, involve workers in the evaluation, measure outcomes rigorously, and scale based on data.
💡 Lesson for Safety Leaders: Ford's approach — UAW-funded pilot, worker co-design, data-driven scaling — is a repeatable model. Partner with a qualified exoskeleton provider, run a 90-day pilot in your highest-overhead task area, and measure both injury data and worker satisfaction before committing to a full rollout.
💡 Want to Learn More?
Next Reality Robotics helps organizations evaluate, pilot, and deploy workplace exoskeleton solutions. Subscribe to The Workplace Ergonomics Brief for weekly insights delivered to your inbox.