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Introduction: Risk assessment at workplaces with high physical workload is essential to derive ergonomic workplace redesign and other preventive measures. With the completion of the MEGAPHYS project in 2018, six major types of physical workload were distinguished and defined (manual lifting, holding, and carrying of loads, manual pushing and pulling of loads, manual handling operations, whole-body forces, body movement and working in awkward body postures). Respectively six specific Key Indicator Methods (KIM), one for each of these six archetypes of physical workload were developed or re-developed. The new KIM allow for each archetype of physical workload to summarize tasks with different intensities of workload within a workday using algorithms. These algorithms are integrated in an additional Key Indicator Method (KIM-Multi-E). All KIM are available since 2019/20 for the workplace risk assessment of high physical workload. The methods were validated regarding different aspects as part of the project MEGAPHYS and therefore recommended for use in operational practice. In addition, the method inventory was completed in 2022 with a basic check and initial screening as the first step in the workplace risk assessment. The method inventory offers an easy-to-use, transparent and cost-effective way to create a risk assessment for physical workloads, which is freely available and has low application requirements. It is therefore recommended by federal regulations in Germany and frequently used in occupational safety in Germany and the EU.

Methods/Results/Discussion: This contribution is intended to provide an overview of the current status of the methods, their possibilities and limitations as well as future challenges that are seen. Reference is made, as an example, to feedbacks and inquiries from practitioners who ask the BAuA via the information center since 2020.

In this context, in addition to aspects of method optimization of single KIM and certain key indicators within the KIM to improve method quality (e.g., by reallocating rating points based on laboratory measurements), aspects of the further digitalization of the method or the support through digital technologies should be highlighted.

Furthermore, an outlook on aim and design of a planned research project “Risk assessment of physical stress during mixed work using the example of nursing professions – Further development of the key indicator method inventory”, will be given. The project combines experimental laboratory and field measurements and is intended to provide information on how different types of workloads could be aggregated within the method inventory.