Wearable sensors in Industry 4.0: Preventing work-related musculoskeletal disorders

Work-related musculoskeletal disorders (WMSDs) are a global health and economic challenge, particularly in industrialized nations, accounting for up to 2 % of GDP losses due to disability and productivity reduction. Wearable sensors, driven by Industry 4.0 advancements, offer transformative potential for real-time ergonomic assessment and injury prevention. This systematic review analyzes 40 peer-reviewed studies (2013–2024) to evaluate the application of inertial measurement units (IMUs), electromyography (EMG) sensors, and pressure sensors in mitigating WMSD risks. Findings demonstrate that wearable technologies enhance workplace safety through real-time feedback, reducing ergonomic risks and improving productivity. Despite promising advancements, challenges such as scalability, user comfort, and data privacy persist. This review emphasizes the need for standardized protocols, ethical frameworks, and deeper integration with machine learning to optimize sensor accuracy and usability. Future research directions include advancing AI-driven predictive ergonomics, addressing privacy concerns, and improving sensor design for widespread industrial adoption. This study provides actionable insights to bridge the gap between academic research and practical deployment in diverse industrial settings. • Reviewed 40 studies on IMUs, EMG, and pressure sensors in construction, healthcare, and manufacturing. • Wearables achieved 95% accuracy in posture correction and fatigue monitoring to reduce injuries. • ML integration improved sensor accuracy, reaching 98.6% in classifying physical workload levels. • Identified key adoption barriers: scalability, user comfort, and privacy issues. • Proposed protocols, ethics, and AI-based tools to improve WMSD prevention via wearables.