Over the past few years, safety and health have become major concerns in the warehouse and logistics sectors. Each year, warehouse fatalities, injuries, and accidents cause unrecoverable losses and huge financial costs. In spite of all the advancements in methods, tools, equipment, and regulations, the number of accidents, especially fatal ones, has not subsided significantly. As a result, safety professionals and researchers have explored new and innovative ways to combat this problem. In the circular logistics facility (CLF) industry, located inside warehouses and providing human muscle-oriented services to maintain pallets, both short-term safety incidents and long-term health concerns are present. Long-term health training is rarely discussed in the literature compared to short-term safety training. This is because health issues are more complex than safety issues, since biological outcomes may take time to develop, are affected by multiple resources, and cumulative injuries may occur. This paper contributes to warehouse health and safety by designing and developing a modular XR collaborative training and testing platform (MXC-P). The co-design process is applied to design each module in the MXC-P. Three main modules related to health and safety training for CLF were considered, namely personal protection equipment, pallet handling, and pallet repairing. On this platform, a virtual interactive world provides a solid hands-on training environment and generates syntactic data for evaluating long-term health risks. On the other hand, collaborative and modular environments provide a solution to geographically distributed systems, allowing employees to connect and train remotely. The effectiveness of the MXC-P is compared with traditional safety training in a pilot study. Based on the results, we can establish that the MXC-P is effective in teaching and testing hazard identification situations, especially those relating to short-term health. The results also indicate that trainees’ recall of knowledge would improve with the MXC-P. In addition to this, the MXC-P can also be used to test and evaluate a new system and generate syntactic data for evaluating long-term health.
