Assessing Ergonomic Risks in Laser Cutting Sheet Metal Operations Using REBA Method: A Case Study

Abstract

The laser cutting of sheet metal, which requires human participation, frequently introduces ergonomic challenges that can negatively impact both worker health and manufacturing productivity. Thus, conducting ergonomic assessments is crucial to identifying and addressing risks associated with workplace design and practices, particularly those related to lifting sheet metal and the potential for musculoskeletal disorders (MSDs). This study uses the Rapid Entire Body Assessment (REBA) method and the Cornell Musculoskeletal Discomfort Questionnaire (CMDQ) to investigate ergonomic risk assessment in laser cutting operations. Data were collected from participants familiar with the tasks through questionnaires and observations, focusing on lower and upper back disorders. The REBA analysis revealed that lifting sheet metal is linked to poor posture and a high risk of lower and upper back disorders, highlighting the need for improvements. Concurrently, CMDQ results highlighted issues related to lower back discomfort and upper back and forearm discomfort, which can detrimentally affect process efficiency. Integrating ergonomic principles into the design process can enhance worker safety and health, increasing productivity and fostering a more sustainable work environment that benefits both employees and the organization.