Carglass: Supporting Employees in Handling Heavy Vehicle Glass

About Carglass and Their Warehouse Operations in Belgium

Carglass is a leading specialist in vehicle glass repair and replacement, serving customers across Belgium and beyond. At their headquarters and main distribution center in Belgium, the team supplies glass for a wide variety of vehicles, ensuring that workshops and service points have the right parts exactly when they’re needed. The work is fast paced, highly precise and physically demanding.

Ergonomic Challenges in Handling Large and Heavy Vehicle Glass

At the Carglass distribution center, employees work daily with large and heavy sheets of vehicle glass. A typical pane weighs between 15 and 20 kilograms and in recent years, glass has been getting larger and heavier. Handling such products is ergonomically challenging, especially when much of the process is still manual.

Jelle Bonroy, HSE Manager at Carglass, explains:

"Vehicular glass is a challenging product to handle ergonomically. We aim to create the best possible work environment, where ergonomics play a crucial role. We are constantly improving: from implementing a spine school to training in safe lifting techniques. Exoskeletons became a natural next step for us."

Selecting the Right Exoskeleton for Warehouse Work

Carglass approached the introduction of exoskeletons methodically. Together with the University of Brussels and their robotics lab, they tested different models to see whether they could bring measurable benefits across workstations. The tests showed clear advantages in terms of support and comfort, leading Carglass to select Auxivo’s solution.

To verify the benefits in a real-world setting, Auxivo conducted on-site measurements with Carglass employees. These field tests recorded muscle activity, body posture, and perceived exertion during typical warehouse tasks. Both with and without the exoskeleton. The results showed that:

• Muscle activity in the lower back was reduced by an average of 25% during lifting and forward-bending tasks.

• The rate of muscle fatigue in the lower back was slowed by around 27%.

• Workers reported a 28% lower perceived effort during their shifts.

• Heart rate during physical work was on average 7% lower, indicating reduced strain on the cardiovascular system.

These results matched the feedback from the teams and confirmed that the exoskeletons could meaningfully reduce physical load in their daily work.

"Auxivo’s big advantage is that it’s easy to use," says Jelle. "It’s lightweight, comfortable, and has no heavy metal parts. That made a difference for our teams."

Implementation Strategy for Exoskeletons in Logistics Operations

The roll-out was gradual, starting with 10 exoskeletons and expanding as feedback came in. Early adopters were enthusiastic, but there was initial skepticism among others. This was addressed by introducing the exoskeletons in groups, rather than to individuals, so that colleagues could experience them together.

Follow-up was another key factor. Each device was adjusted to fit its wearer, and regular feedback sessions ensured that user experiences shaped the next steps. Today, over 50 exoskeletons are in use, and the number is growing.

"At first, it took some getting used to," says Jelle. "Now it feels normal. People come to us asking for one."

Reducing Back Strain and Fatigue in Warehouse Employees

For warehouse operator Thomas, the difference is personal:

"Before using Auxivo, I had frequent lower back pain, especially at the end of the workday. The exoskeleton gives a bit of tension when lifting, which helps you use the correct technique. Now, working without it seems impossible."

Carglass employees report feeling less tired in the evening and experiencing less muscle strain. Combined with the measured reduction in muscle activity and slower fatigue development, the data suggests that the exoskeleton helps make physically demanding work more sustainable.

Long-Term Ergonomics Strategy at Carglass

For Carglass, exoskeletons are now a permanent part of their ergonomic policy. They see them not as a standalone fix, but as one layer in a comprehensive strategy that includes training, workplace adjustments, and ongoing health initiatives.

"Our long-term goal is simple: keep our employees healthy," says Jelle. "Exoskeletons help us do that. They also make Carglass more attractive as an employer. We want to attract healthy people, keep them healthy, and ensure they can work comfortably."