Aligning Computer Vision with Expert Assessment: An Adaptive Hybrid Framework for Real-Time Fatigue Assessment in Smart Manufacturing

To address the high incidence of work-related musculoskeletal disorders (WMSDs) at manual edge-banding workstations in furniture factories, and in an effort to tackle the existing research challenges of poor cumulative risk quantification and inconsistent evaluations, this paper proposes a three-stage system for continuous, automated, non-invasive WMSD risk monitoring. First, MediaPipe 0.10.11 is used to extract 33 key joint coordinates, compute seven types of joint angles, and resolve missing joint data, ensuring biomechanical data integrity for subsequent analysis. Second, joint angles are converted into graded parameters via RULA, REBA, and OWAS criteria, enabling automatic calculation of posture risk scores and grades. Third, an Adaptive Pooling Convolutional Neural Network (CNN) and Long Short-Term Memory Network (LSTM) dual-branch hybrid model based on the Efficient Channel Attention (ECA) mechanism is built, which takes nine-dimensional features as the input to predict expert-rated fatigue states. For validation, 32 experienced female workers performed manual edge-banding tasks, with smartphones capturing videos of the eight work steps to ensure authentic and representative data. The results show the following findings: (1) system ratings strongly correlate with expert evaluations, verifying its validity for posture risk assessment; (2) the hybrid model successfully captures the complex mapping of expert-derived fatigue patterns, outperforming standalone CNN and LSTM models in fatigue prediction—by integrating CNN-based spatial feature extraction and LSTM-based temporal analysis—and accurately maps fatigue indexes while generating intervention recommendations. This study addresses the limitations of traditional manual evaluations (e.g., subjectivity, poor temporal resolution, and inability to capture cumulative risk), providing an engineered solution for WMSD prevention at these workstations and serving as a technical reference for occupational health management in labor-intensive industries.