An Ergonomics Approach Model to Prevention of Occupational Musculoskeletal Injuries

The objective of this study was to prevent occupational musculoskeletal injuries. Our workers stacked boxes of ceramics weighing 10–27 kg, making low back pain common in our enterprise. In all the stacking stations, recommended weight limits (RWL) were separately calculated using the revised National Institute for Occupational Health lifting equation. Since the boxes weighed significantly more than the RWL, we developed a new ergonomic design that completely changed the stacking process. The load put on the workers’ waist vertebrae in the new and the old stacking methods was compared to evaluate the success of the new ergonomic design, using Newton’s third law of motion. Thanks to the new ergonomic design, the load on the workers’ vertebrae decreased by 80%. Due to its simple technology and its very low cost compared to robots, the new ergonomic design can be commonly used in enterprises with repeated and constraining stacking.