Vol. 1, Issue 1, Part A (2025)

Back injuries caused by improper lifting techniques remain a major occupational health concern across labor-intensive industries, contributing to high rates of musculoskeletal disorders, decreased productivity, and substantial economic loss. Traditional manual handling training is commonly used to address these risks; however, its effectiveness often varies due to limited real-time feedback and inconsistent retention of safe lifting behaviors. Recent advances in wearable technology offer new possibilities for enhancing ergonomic training by providing continuous posture monitoring, immediate corrective cues, and data-driven insights into worker technique. This comparative study evaluates the effectiveness of wearable sensor–assisted feedback versus conventional manual handling training in improving lifting biomechanics and reducing lifting-related back-strain injuries among warehouse workers. A sample of 60 participants was divided equally into two groups and underwent a structured 2-week training program followed by a 12-week workplace monitoring period. Biomechanical outcomes—including peak trunk flexion, asymmetry index, and hazardous lift frequency—were recorded using inertial sensors during standardized lifting tasks. Injury incidence and self-reported low-back discomfort were assessed through weekly logs and numerical rating scales. Results show that both groups demonstrated improvement after training; however, the wearable feedback group exhibited significantly greater reductions in trunk flexion, improved movement symmetry, and a sharper decline in hazardous lifting events. Injury occurrence during follow-up was three times lower in the sensor group compared to the manual training group, while discomfort scores showed a more substantial reduction. These findings indicate that wearable feedback enhances motor learning, improves biomechanical safety, and offers a more robust long-term injury-prevention strategy compared to traditional instruction alone. The study concludes that integrating wearable sensor technology into ergonomic training programs can meaningfully reduce back-injury risk and strengthen workplace safety practices.