The Impact of Ergonomic Risk Factors on Musculoskeletal Disorders and Their Implication to Productivity Through Rapid Entire Body Assessment (REBA): A Case Study at ALMED Textiles Plc.

Abstract

Musculoskeletal disorder (MSDs) is one of the most common occupational health conditions globally, especially in the labor-intensive sector like textile & garment manufacturing. This study examines the impact of ergonomic risk factors on the prevalence of MSDs & their implication for the operator’s productivity at ALMEDA Textiles., a major garment manufacturer in Ethiopia. The study employs a cross-sectional design, combining observational method, REBA posture analysis tool along with a validated instruments such as CMSDQ & WPAI questionnaire to comprehensively assess ergonomic risk, & productivity loss. Data were collected from 295 operators across the garment department with a response rate of 93.35%. A key finding revealed that 75.8% of operators have reported symptoms of MSDs, specifically in the lower back, neck, shoulder wrist & knee. MSDs were prevalent, with 34.9% experiencing neck pain and 37.6% experiencing lower back pain daily. productivity losses averaged 43.87%, driven by absenteeism & presenteeism linked to MSDs. The finding also shows 90.8% (REBA score 8-10) of workstations posed high ergonomic risks, primarily due to awkward posture, repetitive motions & prolonged static loading. Regression analysis identified demographic risk factors (β=1.058, P=0.001), job related risk factors (β=0.491, P=0.001), psychological risk factors (β=0.306, P=0.001), & physical risk factors (β=0.187, P=0.008) as significant predictors of MSDs. The study highlights critical gaps in ergonomic training & workstation design, with 95.6% of operators lacking ergonomic awareness. Recommendations include workstation redesign, mechanical aids & targeted training; such measures are vital for reducing MSD risks, improving operator well-being & enhancing productivity. This research contributes to the ergonomic literature in post-conflict industrial settings with a multidimensional view (utilizing a combination of REBA, CMDQ & WPAI) & offers actionable insights for improving worker health & productivity in Ethiopia’s garment industry. For further investigation, researcher should explore the economic return of ergonomics investments analyzing how redesigns, training, & health focused initiatives translate into cost saving & efficiency for manufacturing firms. Relaying solely on self-reported data my introduce response bias due to underreporting or over reporting of symptoms. furthermore, Cross sectional design capture data at a single point in time.