Workstation Design to Reduce Health Impacts on Pallet Repair Workers

Abstract

This study aimed to analyze the causes of ergonomic problems in a wooden pallet repair workstation and to propose guidelines for improving working conditions. Based on statistical data from a company’s infirmary in 2023, it was found that 25% of all service users had musculoskeletal, joint, and bone related problems, of which 16% were employees from the pallet repair section. The study applied two ergonomic risk assessment tools including the NIOSH Lifting Equation and the Rapid Upper Limb Assessment (RULA), with a focus on risk assessment in pallet repair workstations. The findings revealed that lifting pallets from different height levels resulted in a Composite Lifting Index (CLI) of 4.09, indicating a high-risk level. Consequently, the number of stacked pallets was reduced from 10 to 5, and a height-adjustable lift table was installed. These modifications led to a decrease in the CLI to 1.95, and the individual Lifting Index (LI) for the first to fourth pallets dropped to 1.42. In addition, the use of nail guns was found to be prolonged handling of a heavy tool and from the assessment by RULA, it was found to have a score of 6, indicating an urgent need for corrective action. To address this problem, a lifting aid for the nail gun was installed, resulting in a reduction in the RULA score to 3, reflecting a significant reduction in musculoskeletal stress. The results of these improvements clearly demonstrate the effectiveness of ergonomic workstation design in mitigating physical risks to workers.