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.

Scissors in use.Ergonomically designed scissors

Anti fatigue matsWorkers standing position

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.

Stools used by workers.Ergonomic Chairs.

Sewing table in useThe sewing table designed ergonomically

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

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 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…

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

• 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

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