Protocol Approach Based On Ergonomic Risk Analysis In Loading Ice For Tubs In The Operational Area Of A Baking Company

Abstract

This study aimed to diagnose various ergonomic risks in the manual ice handling process at a baking plant, with the objective of proposing a preventive protocol based on scientific evidence and aligned with international ergonomic standards. A quantitative approach was used under an inductive method, applying the REBA (Rapid Entire Body Assessment) tool to evaluate eight critical postures during tasks such as extraction, transportation, emptying, and disintegration of ice bags by operational staff. The results revealed “very high” risk levels in all analyzed postures, particularly those involving lifting from the floor, pushing metal tubs over 280 kg, and repetitive use of metal shovels in cold environments without mechanical assistance. Risk factors such as lack of task rotation, absence of active breaks, inadequate or absent use of personal protective equipment, and limited machinery contributed significantly to the elevated musculoskeletal risk. Based on the findings, a preventive protocol was proposed, structured into three main axes: technical-operational, organizational, and educational. The protocol includes corrective actions such as tool redesign, mechanical assistance, reduction in load weight, continuous ergonomics training, breaks, and evaluations. It also incorporates participatory improvement strategies, continuous worker feedback, and long-term monitoring strategies aimed at improving workplace conditions and employee satisfaction. The study concludes that a comprehensive ergonomic intervention enhances safety, health, and productivity in industrial settings while promoting a preventive culture and improving working conditions over time. These improvements are key to fostering ergonomic awareness among all staff levels.