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Sensor-based online process monitoring has extensive applications, such as in manufacturing and service industries. In real environments, though, sensor data are often contaminated with noise, leading to severe challenges in accurate data analysis. In the existing literature, noise is generally modeled as Gaussian to analyze sensor data for various applications, for example in fault detection and diagnostics. However, in some applications, such as due to challenging field conditions, sensor data may be disturbed by high levels of outliers such that the Gaussian assumption of sensor noise is inadequate, thus leading to large estimation errors. This paper focuses on online classification applications. A robust sparse representation classification method is proposed, which considers non-Gaussian noise, and thus can effectively analyze sensor data with higher levels of outliers. Case studies were completed, based on both numerically simulated sensor data and actual wearable sensor data from occupational manual material handling process monitoring. The proposed classification method could effectively analyze sensor data with non-Gaussian noise, and outperformed commonly used methods in the literature. Thus, this new method may be advantageous for solving classification problems in challenging field conditions, to address the difficulties of high levels of sensor outliers. [ABSTRACT FROM AUTHOR]