Comparing Optical and Custom IoT Inertial Motion Capture Systems for Manual Material Handling Risk Assessment Using the NIOSH Lifting Index

Assessing musculoskeletal disorders (MSDs) in the workplace is vital for improving worker health and safety, reducing costs, and increasing productivity. Traditional hazard identification methods are often inefficient, particularly in detecting complex risks, which may compromise risk management. This study introduces a semi-automatic platform using two motion capture systems—an optical system (OptiTrack®) and a Bluetooth Low Energy (BLE)-based system with inertial measurement units (IMUs), developed at the Biomedical Engineering Laboratory, Universidad de Concepción, Chile. These systems, tested on 20 participants (10 women and 10 men, aged 30 ± 9 years without MSDs), facilitate risk assessments via the digitized NIOSH Index method. Analysis of ergonomically significant variables (H, V, A, D) and calculation of the RWL and LI showed both systems aligned with expected ergonomic standards, although significant differences were observed in vertical displacement (V), horizontal displacement (H), and trunk rotation (A), indicating areas for improvement, especially for the BLE system. The BLE Inertial MoCap system recorded mean heights of 33.87 cm (SD = 4.46) and vertical displacements of 13.17 cm (SD = 4.75), while OptiTrack® recorded mean heights of 30.12 cm (SD = 2.91) and vertical displacements of 15.67 cm (SD = 2.63). Despite the greater variability observed in BLE system measurements, both systems accurately captured vertical vertical absolute displacement (D), with means of 32.05 cm (SD = 7.36) for BLE and 31.80 cm (SD = 3.25) for OptiTrack®. Performance analysis showed high precision for both systems, with BLE and OptiTrack® achieving precision rates of 98.5%. Sensitivity, however, was lower for BLE (97.5%) compared to OptiTrack® (98.7%). The BLE system’s F1 score was 97.9%, while OptiTrack® scored 98.6%, indicating both systems can reliably assess ergonomic risk. These findings demonstrate the potential of using BLE-based IMUs for workplace ergonomics, though further improvements in measurement accuracy are needed. The user-friendly BLE-based system and semi-automatic platform significantly enhance risk assessment efficiency across various workplace environments.