It is known that lifting tasks are one of the risk factors of musculoskeletal disorders in the automotive industry.
Extensive research has been carried out over the years to develop guidelines and determine safe limits in which an
individual can lift. For this reason, the objective of this study is to determine the significant risk factors of
musculoskeletal discomfort among manual lifting task workers in the automotive industry, and propose a
methodological framework for future research on manual lifting tasks. The subjects of this study comprise 211
manual material handling workers from the automotive industry. The subjects completed a set of questionnaires
which are used to elicit information on their demographic characteristics, as well as physical factors and the
prevalence of musculoskeletal discomfort. The Chi-Square test was used to determine the relationship between the
risk factors and musculoskeletal discomfort. The findings of the study show that the following postures (trunk bent
slightly forwards, hands above the knee level (p < 0.05), trunk twisted (over 45o) and bent sideways (p < 0.05) are
the significant risk factors of musculoskeletal discomfort among manual lifting task workers in the automotive
industry. A methodological framework on manual lifting task in the automotive industry is proposed based on the
findings of this study. The framework is developed based on the need to model human lifting capabilities so that task
demands can be designed to fit the workers’ capacity when performing lifting tasks.