Lightweight Vision Transformer for Frame-Level Ergonomic Posture Classification in Industrial Workflows

Abstract

Work-related musculoskeletal disorders (WMSDs) are a leading concern in industrial ergonomics, often stemming from sustained non-neutral postures and repetitive tasks. This paper presents a vision-based framework for real-time, frame-level ergonomic risk classification using a lightweight Vision Transformer (ViT). The proposed system operates directly on raw RGB images without requiring skeleton reconstruction, joint angle estimation, or image segmentation. A single ViT model simultaneously classifies eight anatomical regions, enabling efficient multi-label posture assessment. Training is supervised using a multimodal dataset acquired from synchronized RGB video and full-body inertial motion capture, with ergonomic risk labels derived from RULA scores computed on joint kinematics. The system is validated on realistic, simulated industrial tasks that include common challenges such as occlusion and posture variability. Experimental results show that the ViT model achieves state-of-the-art performance, with F1-scores exceeding 0.99 and AUC values above 0.996 across all regions. Compared to previous CNN-based system, the proposed model improves classification accuracy and generalizability while reducing complexity and enabling real-time inference on edge devices. These findings demonstrate the model’s potential for unobtrusive, scalable ergonomic risk monitoring in real-world manufacturing environments.