AI-Powered Manual Handling & MSD Assessments

AI technology is changing how organisations identify and manage musculoskeletal disorder (MSD) risk. The FlashAI app and RiskAI Web Portal bring together real-time motion analysis and company-wide risk management in a system that works alongside expert Ergonomics consultancy.

I am the affiliate point of contact for this technology in Northern Ireland and Ireland.

FlashAI: Smartphone MSD Risk Assessment

The FlashAI app uses AI-powered motion capture technology to analyse joint movements in real time and detect potential injury risks. Using a smartphone or tablet, your team can capture risk data on any task in seconds, with results available immediately on any web-enabled device.

The app analyses manual handling, pushing and pulling, repetitive upper limb tasks and awkward postures including bending, reaching, twisting and overhead work. Results are presented as a Red/Yellow/Green risk triage alongside a full body map showing joint-specific risk levels.

Assessment methods generated:

  • MAC (Manual Handling Assessment Charts): lifting and carrying

  • RAPP (Risk Assessment of Pushing and Pulling): wheeled and non-wheeled equipment

  • ART (Assessment of Repetitive Tasks of the Upper Limbs)

  • REBA (Rapid Entire Body Assessment)

  • NIOSH Lifting Equation

  • Detailed kinematics and kinetics analysis including low back compression

Each assessment produces:

  • Overall joint and body risk scores

  • Body mapping with joint-specific risk levels

  • Recovery time and cost estimates

  • Specific risk mitigation recommendations

  • Video overlay showing the movement patterns driving risk

  • PDF report ready for HSE compliance records

FlashAI supports 30+ workplace movements with the library continuing to grow. Supported video formats include MP4, MOV, M4V, AVI and WMV.

Where previously a manual workplace assessment could take two hours or more, FlashAI reduces that to 3–5 minutes. This allows Health and Safety teams to assess more tasks, more frequently and to triage risk across their entire operation rather than focusing only on the highest-risk roles.

RiskAI Web Portal

Every FlashAI assessment feeds directly into the RiskAI Web Portal, a cloud-based platform for company-wide risk management that aggregates risk data across tasks, employees, departments and sites.

Where FlashAI provides the individual task assessment, the RiskAI Web Portal gives Health and Safety teams and leadership the broader organisational picture.

The portal provides:

  • Organisational risk and mitigation scores across all tasks and departments

  • Leaderboards showing areas of highest and lowest risk

  • Tracking of mitigation efforts and reassessment progress

  • Detailed video overlays and PDF risk reports

  • Web-based advanced task assessment capability

  • API availability for integration with existing systems

Risk data is presented in a format that supports both operational decisions on the floor and strategic decisions at leadership level. Organisations can track whether interventions are working, demonstrate duty of care and target resources where they are most needed.

How the System Works in Practice

Most organisations can only assess a fraction of their manual tasks. The FlashAI app makes comprehensive coverage practical by enabling Health and Safety teams to conduct routine assessments independently using a smartphone or tablet, with results feeding directly into the RiskAI Web Portal for ongoing monitoring.

The FlashAI app is well suited to routine task screening and high-volume assessment. For complex scenarios, high-risk activities or situations where whole-body posture cannot be fully captured, a professional Ergonomics assessment remains the most appropriate approach. Expert Ergonomics consultancy is available separately for these cases. [Find out more about MSD risk assessments →]

The result is a clearer picture of MSD risk across the operation, with the data to support action at every level.

Find Out More

Get in touch to arrange a 15-minute call. This is not a sales call. We can discuss whether the technology might suit your operations and whether there are any wider Ergonomics assessment or consultancy needs I can help with.

If you're happy to go ahead, I pass your details to the delivery partner. They contact you directly to arrange a live demonstration and handle trial onboarding and platform training.

New organisations can access

  • 6 months free FlashAI access

  • 2-week RiskAI Web Portal trial

Need a more in-depth discussion after you have trial data?

While the tool is highly effective at identifying and scoring risk, it has limitations. It does not tell you why a technique is poor or what is causing it. That is where professional Ergonomics input adds value, interpreting what the data is flagging, identifying the root cause and determining effective ways to eliminate or reduce the risk.

The following are available as separate consultancy services:

  • An on-site conversation about how to approach Ergonomics risk management in your operations

  • Interpretation of findings

  • Recommendations and action planning based on what the data identifies

    Complete the form below to get in touch.