Ergonomic issues in apparel industry
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Transcript of Ergonomic issues in apparel industry
ERGONOMICS IMPLEMENTATION
Presented By:-Abinash MohantyAnurag SinghAvinash KumarShashi PaswanVipin KushwahaDFT-VII
About Ergonomics…
• Ergonomics is a science that focuses on designing 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
hand are very heavy and create a
substantial risk of low back injury.
•Limiting the weight of the bolt
•Use fork lifters to lift the bolt
•Poor Posture during placing the Spreader
bar in fabric bolt
•Use bolt stand to keep the fabric bolt in
sloped position
•Extreme postures during fabric cutting-
Excessive reaching with shoulders and
back. Poor wrist postures and Hand or arm
vibration and contact pressure on the hand
when stapling the pattern to the fabric or
perforating the layers of fabric.
•Improve shoulder and back posture by
setting the appropriate height of table and
cutter according to worker
•Extend the handle and cut from both sides
of the table to reduce excessive reaching.
Extreme postures required when cutting with an electric cutter
Placing spreader bar in the bolt of fabric
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
trimming.
•Scissor handles are narrow and create
contact stresses.
•Scissors are dull and require excessive
force to operate.
•Ergonomically designed scissors and
cutting equipment help reduce contact
stresses.
•They also offer comfortable cutting posture
and lesser force.
•Working in a standing position on a regular
basis can cause sore feet, swelling of the
legs, muscular fatigue, low back pain,
stiffness in the neck and shoulders, and
other health problems.
•Use Anti-fatigue mats
•Anti-fatigue mats promote better
circulation and reduce fatigue in
the lower extremities.
Problems/Solutions in Sewing SectionProblem Solution
•Chairs have no heightadjustable options, back rest and cushioning.
•The chair must be designed ergonomically. Its essential features must include back support, 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 towork with the elbows down, closeto the body.•Employees should have to reachno farther than 18 inches to thefront.•Employees should be able to resttheir arms, but not against sharpedges.•Employees should not have totwist or bend to pick up or putdown objects.
Contd…
Problem Solution
•With no table height adjustment
options the worker had to maintain
awkward postures
• 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.
•Table edges should be padded or
rounded to enhance the blood
circulation
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 work-
related musculoskeletal disorders.
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…
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?
Hands and fingers of the sewing operators get stiff due to inflammation in the median nerve, caused by repetitive actions.
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.
Pain felt in the elbow joints 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…
•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
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
• 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
Work Enhancements