This study aims to improve ergonomic conditions for box-lifting operators in bottled drinking water companies. Operators handling small packaging sizes (600 ml) report significant pain, as revealed by the Nordic Body Map Questionnaire. Addressing this issue is crucial for preventing manual lifting injuries and ensuring worker safety in logistic distribution. A combination of biomechanical analysis, anthropometric data, and the Nordic Body Map Questionnaire was used to assess operator complaints and evaluate ergonomic hazards. The study utilized Catia software to simulate work facility designs, focusing on the development of an adjustable-height hydraulic pallet to optimize operator posture during lifting tasks. Key metrics included compressive and shear force calculations to evaluate injury risks. Operators reported pain in the shoulders, lower back, buttocks, and thighs over the past year. Initial evaluations showed excessive compressive forces (up to 19,778.2 N) and shear forces (over 500 N), indicating a high risk of injury. After ergonomic interventions, simulations recorded compressive forces of 3,350 N and shear forces of 185.31 N, demonstrating a significant reduction in risk and safe operational conditions. This study offers a novel, comprehensive approach to ergonomic optimization in logistics, combining operator feedback, biomechanical analysis, and technological tools like Catia for facility design. The findings provide a blueprint for improving worker safety and efficiency in manual lifting tasks. The study’s outcomes benefit safety engineers, ergonomic specialists, and logistics managers, offering insights into improving worker well-being and operational efficiency. Future research could explore further technological enhancements in facility design and their impact on worker ergonomics.
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