Introducing the Revamped PLI: A Versatile Tool for Efficient Workplace Risk Assessment

ABSTRACT Currently, practitioners face the challenge of selecting assessment tools based on self‐report, observational measurements, or direct measurements while considering time and budget constraints. This selection process can be time‐consuming and discouraging for practitioners, potentially deterring risk assessments. As a tool designed for lumbar load assessment self‐reports, the Physical Load Index (PLI) accommodates all data collection methods, providing an index with three primary input factors (postures, repetition/frequency, and force/load), which gives it the potential to be compatible with all data collection methods and incorporate a comprehensive set of risk factors. However, the inherent subjectivity involved in self‐reporting and the lack of risk categories hinder it development as a versatile assessment tool. This study proposes a Revamped PLI, comprising: (1) The illustration of objective data collection for postures, weights, and frequencies. (2) The elimination of impractical body postures through overlap analysis. (3) The creation of five risk categories based on the score range. Subsequently, the comparison based on 92 industrial tasks confirms its reliable risk assessment by comparing it with REBA. The Revamped PLI simplifies tool selection and effectively facilitates the reduction of ergonomic risks in industries.