📄 Sciences Methods and Technologies
International Journal (SciMeTech)

Volume 2 · Issue 1 · 2026
ISSN: 3085-5284
Cognitive and Physical Workload in Lean Work Systems and Work-limiting Musculoskeletal Symptoms: Evidence from Moroccan Industries
Yasmine Benhammane, Naoufal Sefiani
Pages 27–33 · University Abdelmalek Essaadi
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Abstract
Lean production systems are often promoted for improving efficiency, yet their implications for worker health remain debated, particularly regarding musculoskeletal disorders (MSDs). This study examines how cognitive workload and perceived physical effort are associated with work-limiting musculoskeletal symptoms in Lean production environments in Morocco. A quantitative cross-sectional study was conducted among 150 workers operating in Lean contexts. Cognitive workload was assessed using a composite measure derived from the NASA Task Load Index, while physical effort was measured using the Borg CR-10 scale. Musculoskeletal outcomes were assessed using items from the Nordic Musculoskeletal Questionnaire, with the primary outcome defined as the presence of at least one work-limiting musculoskeletal symptom. Logistic regression analysis was used to estimate the likelihood of work-limiting MSDs as a function of cognitive workload and physical effort, controlling for professional seniority. Exploratory analyses examined differences in workload exposure across seniority groups.

Both cognitive workload and perceived physical effort were significantly associated with an increased likelihood of experiencing work-limiting musculoskeletal symptoms. These associations remained significant after controlling for seniority, which did not emerge as a significant predictor. Exploratory analyses indicated that levels of cognitive workload and physical effort varied across seniority categories, suggesting differentiated exposure patterns within Lean work systems.

The findings indicate that work-limiting musculoskeletal symptoms in Lean production environments are shaped by the combined effects of cognitive and physical workload demands rather than by experience alone. By integrating cognitive workload into the analysis of musculoskeletal outcomes, this study highlights the need to move beyond purely biomechanical perspectives and to consider system-level work design factors. Sustainable prevention of MSDs in Lean contexts requires explicit attention to both cognitive and physical demands embedded in the organization of work.
Keywords: Lean production, Cognitive workload, Musculoskeletal disorders, Physical effort, Occupational health

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SciMeTech · Volume 2, Issue 1 · 2026 · ISSN 3085-5284