Assessing Occupational Musculoskeletal Risks in the Automotive Manufacturing Industry

Thesis Abstract

Occupational musculoskeletal disorders (MSDs) represent a significant health concern within the automotive manufacturing industry, characterized by repetitive tasks, prolonged static postures, and manual handling tasks that elevate the risk of musculoskeletal injuries among workers. Despite the industry's technological advancements, a substantial proportion of employees continued to report symptoms associated with MSDs, underscoring the necessity for comprehensive risk assessments tailored to specific manufacturing environments. This study aims to evaluate the prevalence, determinants, and risk factors of occupational musculoskeletal risks within automotive manufacturing facilities, with the overarching goal of informing targeted intervention strategies. The specific objectives include identifying prevalent musculoskeletal complaints among workers, examining ergonomic and organizational factors contributing to risks, assessing workers' awareness and adherence to safety practices, and proposing evidence-based recommendations for risk mitigation. The study adopts a mixed-methods research design, combining quantitative and qualitative approaches to capture a holistic understanding of the issue. The quantitative component employs a cross-sectional survey administered to a representative sample of 450 automotive assembly line workers across three manufacturing plants, selected through stratified random sampling. Data collection instruments include the Nordic Musculoskeletal Questionnaire (NMQ) to assess symptom prevalence and a structured ergonomic evaluation checklist to identify ergonomic hazards. Additionally, organizational and safety practice data are obtained via structured interviews and workplace observations. The qualitative component involves focus group discussions (FGDs) with 30 workers and key informant interviews with safety managers, providing contextual insights into risk perceptions and safety culture. Data analysis employs descriptive statistics, chi-square tests, and multiple logistic regression analyses to identify key predictors of MSD risk, complemented by thematic analysis of qualitative data to elucidate perceptions and organizational influences. It is anticipated that the findings will reveal a high prevalence of MSD symptoms, particularly in the lower back, shoulders, and wrists, correlated with ergonomic exposures such as awkward postures, repetitive motions, and manual handling tasks. The study expects to identify significant associations between ergonomic risk factors and reported symptoms, with organizational practices and safety awareness mediating these relationships. The analysis aims to quantify the extent of risk exposure and elucidate patterns across different job roles and shift systems. The contributions to knowledge include the development of a context-specific risk assessment framework that integrates ergonomic, organizational, and individual factors, filling existing research gaps regarding comprehensive interventions in automotive settings. The study further advances understanding of how organizational safety culture influences risk perception and behavior among workers. The main conclusion emphasizes the urgent need for targeted ergonomic interventions, employee training, and organizational policy enhancements to reduce MSD risks. Recommendations include the implementation of ergonomic redesigns, regular risk assessments, targeted employee education programs, and strengthened safety management systems. The study underscores the importance of integrating ergonomic principles into manufacturing processes and fostering a safety culture that prioritizes worker health. This research provides a scientifically validated basis for industry stakeholders to develop sustainable, evidence-based occupational health strategies, ultimately contributing to improved worker well-being, productivity, and industry standards in occupational safety.