Redesigning Workdesks Using Ergonomic Function Deployment (EFD) to Reduce Musculoskeletal Risks for Warehouse Operators

Abstract

Inergonomic workstation design significantly amplifies the risk of Work-Related Musculoskeletal Disorders (WMSDs). This study addresses ergonomic challenges faced by scan-in finished goods operators at a metal manufacturing company, who endure static standing postures for seven hours daily using a workdesk that is excessively high and narrow.
Objective: This study aims to redesign the workstation to mitigate musculoskeletal risks and improve working postures using the Ergonomic Function Deployment (EFD) method.
The EFD approach was utilized to integrate operator needs with ergonomic principles through the House of Ergonomics (HOE). Baseline musculoskeletal complaints were assessed using the Nordic Body Map (NBM) questionnaire, while working postures were evaluated via Rapid Upper Limb Assessment (RULA). The design dimensions were developed based on representative Indonesian anthropometric data combined with field observations.
The NBM survey revealed significant discomfort in the feet (66.67%), ankles (66.67%), and calves (33.33%), indicating high-risk levels. To resolve this, an adjustable workdesk (height ranging 102–112 cm) integrated with an ergonomic standing-support stool and footrest was developed. Post-implementation RULA analysis demonstrated a significant risk reduction, with the final posture score dropping from 4 (medium risk) to 2 (acceptable posture).
The EFD-based workdesk redesign effectively minimizes musculoskeletal risks, enhances operator comfort, and promotes sustainable ergonomic principles in warehouse logistics.