Assessment and redesign proposals of musculoskeletal risks at work in an industrial packaging workstation

Abstract

Work-related musculoskeletal disorders (WMSDs) remain a significant challenge in occupational health, particularly within industrial packaging environments characterized by prolonged standing, non-neutral body postures, and repetitive tasks. To address this issue, this study investigated the ergonomic hazards present at an industrial packaging station to propose redesign strategies aimed at mitigating physical strain. A mixed-methods approach was utilized, integrating the Rapid Entire Body Assessment (REBA) tool with direct workplace observations and structured operator interviews. The acquired data revealed a baseline REBA score of 9, indicating a high risk of musculoskeletal injuries, impacting the lower back, shoulders, and wrists. This elevated risk profile is primarily attributed to the physical demands of the operation, including long standing on hard surfaces, continuous arm movements, constant overhead stretching, and excessive forward trunk flexion. Although the ambient environmental parameters, such as temperature and lighting, passed basic ergonomic checks, employees still dealt with localized pain on a daily basis. On top of that, they pointed out structural problems with suboptimal tool organization and general safety standards. Based on these diagnostic findings, a series of practical, low to moderate cost ergonomic interventions is proposed. Equipping the station with anti-fatigue mats, reorganizing supplies for better accessibility, and utilizing adjustable worktables should noticeably decrease bodily strain. Implementing these specific changes will likely lower the overall number of WMSD cases throughout the industrial packaging sector.