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Assessing the Risk of Musculoskeletal Injuries of Workers at the Warehousing Workstation of Iran Tire Company

Authors :

Mahshad Nazari Jeirani¹ Amirhossein Mohammadzadeh² Seyedeh Shokouh Azam Mirdamadi³ Mohadeseh Sadat Shahangian⁴ Navid Arjmand⁵

1- Department of Mechanical Engineering / Sharif University of Technology 2- Department of Mechanical Engineering / Sharif University of Technology 3- Department of Mechanical Engineering / University of Tehran 4- Department of Mechanical Engineering / University of Tehran 5- Department of Mechanical Engineering / Sharif University of Technology

Keywords :

musculoskeletal risk assessment،tire handling،ergonomic interventions،low back pain،manual material handling

Abstract :

Musculoskeletal disorders are a persistent concern of occupational injuries, particularly in tasks involving repetitive manual material handling (MMH). This study investigates the ergonomic and biomechanical risks associated with tire lifting and loading tasks performed by warehouse workers at Iran Tire Company. To identify the most critical posture, a simplified video-based motion analysis was conducted, followed by simulations using multiple biomechanical modeling platforms. The highest-risk posture produced L4-L5 compression forces of about 4800-5000 N for the 14 kg tire and 3000-3200 N for the 7 kg tire, exceeding the 3400 N safety threshold in most cases. This posture was then evaluated using both biomechanical and ergonomic assessment tools. Based on the results, two interventions were introduced: (1) an engineering control involving a height-adjustable pallet jack to minimize trunk flexion, and (2) an administrative strategy to reduce task frequency, which reduced compression forces to about 2500-2700 N for the 14 kg tire and 1500-1600 N for the 7 kg tire. Post-intervention evaluations revealed a substantial reduction in lumbar spine loading and ergonomic risk scores, highlighting the effectiveness of low-cost ergonomic solutions in enhancing worker safety and reducing the risk of MSDs in manufacturing environments.