Ergonomic Issues In Apparel Industry 6i1451

ERGONOMICS IMPLEMENTATION Presented By:Abinash Mohanty Anurag Singh Avinash Kumar Shashi Paswan Vipin Kushwaha DFT-VII

About Ergonomics… • Ergonomics is a science that focuses on deg a job for

the worker. • An ergonomically-designed job would ensure that a taller

worker had enough space to safely perform his/her job, and also that a shorter worker could reach all of his/her tools and products without reaching beyond a comfortable and safe range.

Fundamental Principles • Use proper tools • Keep repetitive motions to a minimum • Avoid awkward postures • Use safe lifting procedures • Get proper rest

Injuries and Illnesses Among Apparel Workers •

70% of Sewing Machine Operators Using Foot Controls Report Back Pain

•

35% Report Persistent Low Back Pain

•

25% Have Suffered a Compensable Cumulative Trauma Disorder (CTD) – 81% of CTDs Were to the Wrist – 14% of CTDs to the Elbow – 5% of CTDs to the Shoulder – 49% of Workers Experience Pain in the Neck

Tasks Associated With Injuries and Illnesses •

Hand Sewing and Trimming are stressful to all upper limbs

•

Stitching tasks are associated with pain in the Shoulders, Wrists, and Hands

•

Ironing by Hand is associated with Elbow pain

•

Garment Assembly tasks are associated with CTDs of the Hands and Wrists

•

Foot Operated Sewing is associated with pain in the Back

Problems/Solutions in Spreading Cutting Section Problem

Solution

•Loading by hand- Bolts of fabric lifted by

•Limiting the weight of the bolt

hand are very heavy and create a

•Use fork lifters to lift the bolt

substantial risk of low back injury.

•Poor Posture during placing the Spreader

•Use bolt stand to keep the fabric bolt in

bar in fabric bolt

sloped position

•Extreme postures during fabric cutting-

•Improve shoulder and back posture by

Excessive reaching with shoulders and

setting the appropriate height of table and

back. Poor wrist postures and Hand or arm

cutter according to worker

vibration and pressure on the hand

•Extend the handle and cut from both sides

when stapling the pattern to the fabric or

of the table to reduce excessive reaching.

perforating the layers of fabric.

Placing spreader bar in the bolt of fabric

Extreme postures required when cutting with an electric cutter

Hand-made bolt stand, used to assist lifting a bolt into a tall spreader

Automated cutter that would benefit from controls in a more accessible location

Contd... Problem

Solution

•Large, heavy scissors are used for

•Ergonomically designed scissors and

trimming.

cutting equipment help reduce

•Scissor handles are narrow and create

stresses.

stresses.

•They also offer comfortable cutting posture

•Scissors are dull and require excessive

and lesser force.

force to operate.

•Working in a standing position on a regular •Use Anti-fatigue mats basis can cause sore feet, swelling of the

•Anti-fatigue mats promote better

legs, muscular fatigue, low back pain,

circulation and reduce fatigue in

stiffness in the neck and shoulders, and

the lower extremities.

other health problems.

Scissors in use.

Workers standing position

Ergonomically designed scissors

Anti fatigue mats

Problems/Solutions in Sewing Section

Problem

Solution

•Chairs have no height adjustable options, back rest and cushioning.

•The chair must be designed ergonomically. Its essential features must include back , stable legs, height adjustability as per OSHA

•Sewing tables are not easily adjustable. •Almost all sewing tables are flat. Flat sewing tables do not maximize visibility and compromise the posture of the upper extremity and neck. •Sewing machine operators have limited legroom because of drawers attached to the underside of the table.

•Employees should be able to work with the elbows down, close to the body. •Employees should have to reach no farther than 18 inches to the front. •Employees should be able to rest their arms, but not against sharp edges. •Employees should not have to twist or bend to pick up or put down objects.

Stools used by workers.

Sewing table in use

Ergonomic Chairs.

The sewing table designed ergonomically

Contd… Problem

Solution

•With no table height adjustment

•Table edges should be padded or

options the worker had to maintain

rounded to enhance the blood

awkward postures

circulation

• Employee had to lean on sharp edges creating a lot of discomfort •Employees resting forearms or wrists on sharp edges may cut off blood circulation, pinch nerves, and cause injury to the arms or hands.

Workers arm resting on sharp edges.

Table edges should be padded or rounded

Reasons for such Ergonomic Issues •The majority of the sewing machine workstations currently in use are designed without the comfort, health or convenience of the sewing machine operator in mind . •The sewing machine operators generally work in a seated position at poorly designed workstations, performing the same operation during the entire course of the workday, the risk of developing musculoskeletal disorders is high. •The poor postures resulting from the conditions described above, combined with highly repetitive, time-pressured work, has resulted in high rates of workrelated musculoskeletal disorders.

Contd… Workers leaning forward on the machine while stitching of parts. This can cause problems in the back and neck regions of the workers.

Absence of backrests in the chairs provided to the workers in the sewing department. This can cause lower back region difficulties among the workers.

Contd… Employees resting forearms or wrists on sharp edges may cut off blood circulation, pinch nerves, and cause injury to the arms or hands.

Doing the same action repeatedly makes it very much tiring for the workers, and can cause fatigue and stiffening in their fingers.

How it affects?

Tremendous pain in the lower back region, caused due to prolonged hours of sitting at the sewing machines is felt by the workers. It even interferes with the ability to naturally bend their bodies.

Hands and fingers of the sewing operators get stiff due to inflammation in the median nerve, caused by repetitive actions.

Pain felt in the elbow ts caused by the force imparted while stitching. The pressure of completing the work in a limited time period increases the stress on the workers.

Leaning on the machines while stitching causes immense pain in the spine of the sewing operators.

Sewing operators also face pain in the neck and at the shoulders.

Measures that can be taken •Certain infrastructure can be improved keeping in mind the comfort of the workers and working postures. •They should be given proper training to maintain a healthy working condition. •Skilled doctors and physiotherapists should be provided for the assistance of the employees. •Workers should be allowed to take breaks in between their works, and even change works. •Sewing tables should be provided with adjustable chairs and proper back rests. •Anti-Fatigue mats must be introduced for workers required to stand for long hours at a stretch.

Contd…

Contd… •Ergonomic Sewing Operator Chair Net weight 26 lb – 11.8 kg Seat dimensions 20.5" x 20.5“ Back rest dimensions 18.5" x 17.5" Seat height adjustment 15" x 21“ FEATURES • Height adjustment • Contoured cushion • Waterfall seat edge • Tilt and lock mechanism • Back height adjustment

Recommendations for tables

WorkStation Redesign - Sewing Machines • • • • • •

30” Fixed Tabletop Height Point of Operation Between 4-7” Above Tabletop Sewing Machine Tilted 11o Toward Operator For Jobs of Longer Duration Sewing - Bench Mounted Arm Rests Adjustable Chair Adjustable Foot Rest With Movable Machine Control

Work Enhancements • Foam Padded Edges to Sharp Table Edges • Provide Cloth Upholstered Adjustable Chairs • Angle Packing Boxes to Workers With Tilt Equipment • Provide Anti-Fatigue Matting for Standing Workers • Improved Lighting • Require Rest Periods • Job Rotations

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