PLOT: A Plant-Layout Organizational Tool Software Based on Fatigue Failure Theory for MSD Control and Mitigation

Work-related musculoskeletal disorders (MSDs) remain a leading source of workplace injuries and reduced productivity. While validated ergonomic tools like LiFFT, DUET, and the Shoulder Tool exist, there is currently no integrated system to assess and visualize cumulative MSD risk across multiple body regions, tasks, and workers. The Plant-Layout Organizational Tool (PLOT) addresses this gap by merging these fatigue failure-based assessment tools into an interactive platform that supports facility-wide ergonomic risk mapping. Users input task-specific data (e.g., load, repetitions, exertion), conduct risk assessments, and map results onto facility layouts to visualize exposure at the workstation, line, or section level. Developed in Python, PLOT supports cross-platform deployment and includes robust data filtering, reporting features, and visual summaries. Its capabilities empower users to identify high-risk jobs, evaluate job rotation strategies, and prioritize interventions based on cumulative exposure estimates. By contextualizing ergonomic risks within the physical layout of the workplace, PLOT enhances decision-making and supports more targeted, data-driven prevention strategies. Future development will focus on validation, user feedback integration, and expanded functionalities. PLOT represents a major step forward in applying fatigue failure theory and visual ergonomics to practical MSD control at the organizational level.