Reducing Musculoskeletal Risk at London North Eastern Railway: MOVA MMH pilot

Musculoskeletal Disorders (MSDs) remain one of the leading causes of workplace absence in safety-critical industries. In 2022/23, MSDs were among the top three reasons for absence at LNER, accounting for 17,375 working days lost and £854,000 in absence costs. Traditional manual handling risk assessments rely on one-time observational reviews, which can introduce subjectivity and fail to capture real-world exposure over time. SpatialCortex partnered with LNER to pilot MOVA MMH, an advanced wearable biomechanical technology that enables objective, continuous assessment of manual handling risk. The pilot demonstrated alignment with traditional HSE MAC assessments while reducing assessment time by 75% and providing significantly deeper insight into exposure patterns.

The Challenge

Manual handling risk assessments are typically conducted through observational methods. While widely accepted, these methods present limitations:

• Snapshot assessments that may not reflect true working patterns

• Observer bias and subjectivity

• Limited ability to account for fatigue over time

• No continuous exposure tracking

• Limited consideration of varying anthropometry

LNER sought a more robust, data-led approach to managing musculoskeletal risk.

The Solution: MOVA MMH Wearable Technology

MOVA MMH integrates body-worn motion sensors attachable to standard workwear — including torso and limbs — to capture 3D biomechanical data continuously during live operations. The system records the variables that underpin the HSE's established manual handling assessment frameworks: horizontal and vertical load distance from the lower back, torso posture across three planes of movement (flexion, lateral bend and rotation), postural constraints, and duration of exposure across different risk categories.

This data is processed to produce outputs that align with HSE's Risk Assessment frameworks,

• Manual Handling Assessment Charts (MAC) — the industry-standard tool for assessing lifting, carrying and team handling tasks

• Rapid Assessment of Physical Activity (RAPP), which evaluates pushing and pulling tasks

• Assessment of Repetitive Tasks (ART), which addresses upper limb risk from repetitive work.

Together, these three frameworks cover the full spectrum of manual handling risk encountered in operational environments such as rail, logistics and freight.

Unlike traditional observational methods — which rely on a trained assessor watching a worker for a limited period — MOVA captures true working behaviour across an entire shift. This eliminates observer subjectivity, removes the risk of snapshot bias, and produces continuous, objective biomechanical evidence that is both auditable and legally defensible. Explore MOVA MMH technology here: Manual Handling

Pilot Study: Passenger Assistance Operations

The pilot focused on Passenger Assistance activities, including:

• Boarding and disembarking support

• Luggage handling

• Wheelchair ramp deployment

  
  

Staff delivering Passenger Assistance tasks was wearing a high-viz jacket and trouser with integrated MOVA sensors. Movement and posture data were recorded on MOVA MMH App

continuously as they delivered the task. The App also provided ergonomic risk scores in real-time via the App UI. Assessments were conducted in parallel using traditional observational methodology and MOVA MMH wearable data capture to enable direct comparison.

Results

Validation of risk ratings

MOVA’s overall risk rating aligned with traditional HSE MAC assessments conducted by experienced H&S professionals, confirming reliability and defensibility.

75% reduction in assessment time

Traditional assessments required 1.5–2 hours to complete. MOVA reduced this to approximately 20 minutes, enabling greater coverage and faster implementation of controls.

Continuous risk visibility

MOVA provided real-time insight into when risk thresholds were exceeded, enabling immediate corrective action.

Exposure-based risk intelligence

The system quantified time spent in each risk category and cumulative exposure over a shift, supporting evidence-based decision-making and ALARP compliance.

Strategic impact

The pilot demonstrated that wearable biomechanical technology can transform manual handling assessment from a static compliance process into a dynamic, data-driven safety intelligence system. Benefits include:

✓ Elimination of subjectivity

✓ Full-shift exposure visibility

✓ Detection of fatigue-related risk patterns

✓ Immediate mitigation implementation

✓ Improved H&S team efficiency

The Health & Safety team is now piloting MOVA MMH for wider deployment to quantify long-term reductions in MSD exposure and absence rates.

Scalable across high-risk industries

While conducted in the rail sector, MOVA MMH is applicable across logistics, freight, construction, ports, warehousing, manufacturing, energy, utilities, aviation, ground handling, and healthcare environments where manual handling risk is present.

Conclusion

By moving from observational assessment to biomechanical data capture, organisations can adopt a proactive, measurable approach to Musculoskeletal risk reduction. SpatialCortex’s MOVA MMH solution provides a scalable pathway toward improved workforce wellbeing, operational resilience, and evidence-based safety management.

Read the Case study here:

SpatialCortex_MOVA_Case_Study_LNER.pdf

Download PDF • 190KB

Frequently Asked Questions (FAQs)

What is MOVA MMH and how does it work?

MOVA MMH is a wearable biomechanical assessment system developed by SpatialCortex. It uses motion sensors integrated into standard workwear — including high-visibility jackets and trousers — to capture 3D biomechanical data continuously during live operations. The system records posture, load distance, postural constraints, and time spent in each risk category across an entire working shift. Risk scores are generated automatically and displayed in real time via the MOVA MMH app, allowing immediate corrective action when thresholds are exceeded.

How does MOVA MMH compare to a traditional HSE MAC assessment?

Traditional HSE MAC assessments are conducted by a trained assessor observing a worker for a limited period — typically 90 to 120 minutes — and scoring tasks based on what they observe. MOVA MMH captures biomechanical data continuously across a full shift, eliminating observer subjectivity and snapshot bias. In the LNER pilot, MOVA MMH risk ratings aligned with those produced by experienced H&S professionals using the MAC tool, while reducing assessment time by 75% — from 90–120 minutes to approximately 20 minutes.

What is the HSE MAC assessment and when is it required?

The Manual Handling Assessment Charts (MAC) is a tool published by the Health and Safety Executive (HSE) for assessing the risk of musculoskeletal disorders from lifting, carrying, and team handling tasks. It is the most widely used manual handling risk assessment tool in the UK and is recognised as a standard method for demonstrating compliance with the Manual Handling Operations Regulations 1992. Employers are required to assess manual handling risk where there is a possibility of injury, and the MAC tool provides a structured, evidence-based framework for doing so.

What is the difference between MAC, RAPP and ART?

The HSE publishes three primary manual handling assessment tools, each covering a different category of physical risk. The Manual Handling Assessment Charts (MAC) assess lifting, lowering, carrying, and team handling tasks. The Rapid Assessment of Physical Activity (RAPP) tool assesses pushing and pulling tasks. The Assessment of Repetitive Tasks (ART) tool assesses upper limb risk from repetitive manual work. Together, MAC, RAPP and ART cover the full spectrum of manual handling risk encountered in operational environments. MOVA MMH produces data that aligns with all three frameworks, enabling organisations to address multiple risk categories from a single assessment platform.

Does MOVA MMH replace the need for a qualified H&S assessor?

MOVA MMH does not replace qualified H&S professionals — it enhances their capability. The system automates the data capture and risk scoring process, reducing the time required for an assessment from 90–120 minutes to approximately 20 minutes. This frees H&S teams to focus on intervention design, workforce engagement, and strategic risk management rather than manual observation. All MOVA MMH outputs are reviewed and interpreted by qualified professionals, ensuring that assessment findings remain legally defensible.

Can MOVA MMH data be used for ALARP compliance?

Yes. MOVA MMH produces quantified exposure data — including time spent in each HSE risk category and cumulative biomechanical load across a full shift — that directly supports ALARP (As Low As Reasonably Practicable) documentation. The system generates auditable, objective records of worker exposure that can be used to demonstrate that all reasonably practicable steps have been taken to reduce manual handling risk. In the LNER pilot, MOVA MMH data was used to support evidence-based decision-making and ALARP compliance across passenger assistance operations.

What tasks were assessed during the LNER pilot?

The LNER pilot focused on Passenger Assistance operations, covering boarding and disembarking support, luggage handling, and wheelchair ramp deployment. Staff wore MOVA MMH sensors integrated into their high-visibility workwear throughout their shifts. Assessments were conducted simultaneously using both MOVA MMH and traditional HSE MAC observational methodology, enabling direct comparison of the two approaches under identical working conditions.

How disruptive is wearing MOVA MMH sensors during a shift?

In the LNER pilot, all participating staff reported no disruption to their normal work activities and no discomfort during use. Sensors are integrated directly into standard workwear, meaning workers do not need to wear additional equipment or modify their working practices. This finding is significant in operational environments where workforce acceptance is a key barrier to the adoption of monitoring technology.

Is MOVA MMH suitable for unionised workplaces?

Yes. The LNER pilot was conducted in a unionised operational environment, and all participating workers consented to wear the sensors throughout their shifts. Workforce acceptance was high, with no disruption to normal working practices reported. Transparent communication about the purpose and scope of the assessment — and the fact that data is used to improve working conditions rather than monitor individual performance — is central to successful deployment in unionised settings.

What industries can use MOVA MMH?

MOVA MMH is applicable across any industry where workers perform manual handling tasks. Validated deployments include rail, logistics, freight, ports, and warehousing. The system is also suitable for construction, manufacturing, energy, utilities, aviation ground handling, and healthcare environments. MOVA MMH has been tested across a range of operationally demanding environments — from exposed quayside berths and container yards to busy distribution centre floors — demonstrating its readiness for real-world deployment.

What are musculoskeletal disorders and why do they matter in rail?

Musculoskeletal disorders (MSDs) are injuries and conditions affecting muscles, joints, tendons, ligaments, and the spine. They are among the leading causes of workplace absence in the UK, accounting for approximately 7.1 million lost working days nationally in 2024/25, according to the Health and Safety Executive. In the GB rail industry, RSSB data shows that MSDs cause approximately 1 in 4 days of sickness absence, making them one of the sector's most significant workforce health challenges. Rail workers in physically demanding roles — including passenger assistance, infrastructure maintenance, and freight handling — face elevated MSD risk due to manual handling, awkward postures, and sustained physical exertion across long shifts.

Where can I find out more about MOVA MMH or request a demonstration?

Full information about MOVA MMH, including product specifications, case studies, and deployment options, is available at spatialcortex.co.uk. Organisations interested in piloting MOVA MMH or discussing deployment across their operations can request a demonstration directly through the website.

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SpatialCortex's MOVA MMH is a wearable biomechanical assessment system designed for physically demanding industries including rail, logistics, freight, construction, and healthcare. It captures continuous 3D movement data across full working shifts, producing risk assessments that align with the HSE's MAC, RAPP and ART frameworks. In a pilot with London North Eastern Railway, MOVA MMH reduced manual handling assessment time by 75% — from 90–120 minutes to approximately 20 minutes — while delivering risk ratings consistent with those produced by experienced H&S professionals. The system provides real-time alerts when ergonomic risk thresholds are exceeded and generates cumulative exposure data to support ALARP compliance. MOVA MMH is available in two configurations: MOVA MMH for manual material handling environments, and MOVA SEAT for roles involving prolonged seated operation. Organisations seeking to reduce musculoskeletal disorder risk, improve workforce wellbeing, and build a defensible evidence base for health and safety compliance can request a demonstration at spatialcortex.co.uk.