Engineering innovations in car disassembly systems are studied for affects on system operators’ risk of repetitive strain injury (RSI). Objective instrumented measures of injury risk factors with synchronized video-based task analyses were used to examine changes in operators’ RSI risk during two cases of engineering innovation: 1) a shift in industrial model from traditional extracting saleable parts to line-based full material recovery, and 2) the prospective effects of a simulated “Lean” inspired process improvement in the line system.

Both cases of innovation showed significantly increased movement speeds and reduced muscular recovery opportunities, implying increased RSI risk. This case study reveals a mechanism by which innovation may increase RSI risks for operators. Managers responsible for engineering innovation should ensure their teams have the tools and mandate necessary to control injury hazards as part of the development and design process. These cases suggest how failure to manage RSI hazards in the innovation process may allow increases of injury risks that can compromise operational performance. This “innovation pitfall” has implications for operator health and organizational sustainability. Alternative pathways are discussed.