Cutting Room Ergonomics
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ERGONOMICS
Cutting Room ErgonomicsDate : 10th oct. 2011Presented By -
Abhinay KumarSatyam SinghShrey VijRishab Tandon
Kuldeep Meena
NATIONAL INSTITUTE OF FASHION
TECHNOLOGY, GANDHINAGAR
Under Guidance Of -Mr. Manoj Tiwari
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CUTTING ROOM IN TERMS OFERGONOMICS
Unlike sewing room, the cutting room mostly consists ofequipments and workstations on which work is to be done only instanding position.
So, there must be equipments and workstations designedaccording to the anthropometric data of human body in standingpostures.
The postures are different from the sitting workstations here.
Basically in the standing position the points which are taken underconsideration are workers height, arm length, hand length, Handbreadth etc.
Consideration is taken care of :
Workplace design
Task design
Equipment design
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AVERAGE MEASUREMENTS OF
HUMAN BODY
http://www.disabled-world.com/artman/publish/height-chart.shtml
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ADVANTAGES OF STANDING
WORKSTATION
Reach is greater in standing than in sitting.
Body weight can be used to exert forces.
Standing workers require less leg room than seated
workers.
Lumbar disc pressures are lower.
It can be maintained with little muscular activity andrequires no attention.
Trunk muscle power is twice as large in standing than insemi-standing or sitting.
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STANDARD WORKING POSTURE
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STANDING POSITIONS
IDEAL POSITIONNORMAL POSITION
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IDEAL BODY POSTURE
Maintain the S curve in your spine
Feet flat on the floor
Knees and hips at a 90 degree angle
Elbows at 90 degree angle do not lean on elbows
Shoulders relaxed and elbows close to body
Head and neck in the upright position
Hands and wrist in the neutral positionAvoid: Poor body mechanics, twisted torso, slouching,kneeling, squatting, neck rotation/side bending, bent wrists,and reaching overhead.
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A WORKERS REACH
Usual work area/reach : (80-100 + 25) cm
Occasional work area/reach : (80-100 + 50) cm
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CUTTING DEPARTMENT
The primary tasks in the cutting department are:
Loading the spreading machine
Spreading the fabric
Cutting the fabric
Stacking cut pieces
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LOADING THE SPREADING
MACHINE
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SPREADING THE FABRIC
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CUTTING THE FABRIC
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STACKING THE CUT PIECES
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EQUIPMENTS USED IN CUTTING ROOMAND THEIR ERGONOMICS FEATURES
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SPREADING TABLE
Table dimensions : length - 340(approx.)
Width72
Height34
AdjustableHeight
Air blower beneath
the table
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Ergonomic features of cutting table :
adjustable height
air blower beneath table for easy movement of layers
smooth edges
width according to normal human hand movements
Smooth edgesHeight according to
normal human height
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MANUAL SPREADING MACHINE
Rollers for
movement Points for width sizeadjustment
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Ergonomic features :
width size adjustable
adjustable height according to table and worker
manual edge control
rollers adjustment for easy movement between onetable to another table
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STRAIGHT KNIFE
Handle for bettergrip
Swivel base plate for movement
27 height easy to
handle
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Handle for movement
to other tables
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Ergonomic features :
Weight : 34 lbs(15.4 kg) easily moveable by cuttingperson
Height : 27
For better grip and easy movement extended holderis present
For transportation purpose on the upper part gripper
is present
For steady and vibration free working base plate is ofmetal, 8long and 5broad
a security handle that automatically drops the
presser foot leg and stops the machine when thehandle is released
ergonomic handle that reduces wrist strain
a swivel baseplate that turns easily even in the
hardest materials
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END CUTTER
Long Handle for longer
reach
Control panel in workers
reach Track formovement
of end
cutter
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Ergonomic features :
For easy movement there is a gripper to move theend cutter length wise
Small in size
Attached to table so that the movement is notdependable only on the cutting man i.e. weight ofend cutter is distributed between table and the
cutting man
A long rod is attached to the end cutter to move itwith the table length without the movement of theoperator
Easy to attach and detach with tables
Fitted on the tracks from easy to and fro movementacross the table
Control panels are in the reach of cutting man
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BAND KNIFE
Curve inserted for better
reach to the blade
Emergency
light
ADJUSTABLE
TABLE HEIGHT
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Air flotation tableAdjustable Table height according
human height
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Ergonomic features :
Adjustable table height
Air flotation for easy movement of layers during use
Additional Safety Device to ensure the operatorssafety
The lighting device to reduce operators fatigue
Auto Catch Device, to catch the knife when the blade
is broken.
A curvy portion is provided to fit the cutting man foreasy reach to the blade
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BAND KNIFE WORKERS REACH
25cm80-100cm
50cm
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LABELLING GUN
Handle for grip
Extra plastic griper
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Ergonomic features :
gripper is provided for fast use of the labelling gun
small in size
weight is less
extra plastic grip is also provided
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FUSING MACHINE
Automatic sensor
Control panel near
the operator
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Ergonomic features :
continuous fusing is done so no need to move thecut pieces every time
automatic sensor in case of any emergency
35 height of the machine bed which is according tonormal human height
Control panel is near the operators position to avoidany emergency
Operator friendly side swing design
Operator is protected from heat radiation
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GENERAL ERGONOMIC CONCERNSDURING WORK
Static postures
constantly work with their arms above shoulder level
Awkward body postures
the height of the workstation
Repetition of movements
Standing in one position for long periods of time
No foot rest
Awkward wrist postures
Workers should try not to twist their upper body whenplacing objects besides them
Vibration caused by different equipments
PROBLEM SOLVING TECHNIQUES
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PROBLEM SOLVING TECHNIQUES
Avoid static postures
For standing work, the height of the workstation should allow
workers to function with elbows at 90 degrees
workers should try and sit for short periods of time while
working to give their leg and back muscles a rest
Change position after a period of time
There must be a raised foot rest provided for standing
workstations
majority of work should be done between knuckle height and
shoulder level
Workers should move their feet, instead of twisting at the waist,
in order to face the area where the object is going to be placed
Avoid repetition of movements
Assign job according to worker, not worker according to job
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NORMAL WORK FLOOR ARRANGEMENT
Anti-fatigue mats for those who must stand for extendedperiods of time
Footrest to allow the employee to put one foot up andchange positions often
Floor surface is free of obstacles and flat
Keep work at comfortable height to maintain erectposture
Footwear with good support
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Avoiding MSDs needs Work Smarter,Not Harder
Work in neutral postures
Reduce excessive force & repetition
Keep everything in easy reach and at proper heights
Minimize static unsupported postures and pressurepoints
Use proper lifting
techniques and lift aides
Ask for assistance with difficult tasks
Take micro-breaks (stand, stretch, change tasks)
Maintain a comfortable environment
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GAPS IDENTIFIED IN WORKENVIRONMENT AND
EQUIPMENTS
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AREAS GAPS IDENTIFIED SUPPORTIVE FINDINGS
Cutting table Work height too high Complaints of postural
discomfort and pain in
shoulders, neck and hands
Sorting table Work height too high Complaints of postural
discomfort and pain inshoulders, neck and hands
Inadequate lighting Low level of lighting Complaints of visual strain and
blurred vision
Excessive noise Noise level exceeds 90dB Workers complaints
Dust Increased level in cutting
section
Complaints of respiratory
problems
Hot and humid work place Heat Humidity 23 to 57% Heat
exposure
Workers complaints Identified
as risk factor by hazard
identification and risk
assessment
Blade guard of the cutting
machine
Defects in design of blade
guard, non use of blade guards
Fifty per cent of workers
reported accidental cuts
General safety measure Absence of general safety
measures
Observed gaps
Personal protective equipment Absence of personal protective
devices
Observation and reported
incidences
O O
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SUGGESTED ERGONOMICFEATURES IN CUTTING ROOM
Efficient spacing between the cutting tables, racks, bandknife machine, fusing machines for better movement ofman and material.
Cutting table heights are according to normal human
height
Dustbins are provided according to the height of thecutting table and band knife machine
Racks heights are according to the normal humans hand
reach
Fabric store is near the cutting room so less movementof man and material
The illumination level is kept to standard illumination
level i.e. 750 lx.
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Cont
Provision of local exhaust ventilation that uses suction,based on the principle of a vacuum cleaner, is to beencouraged in the cutting and stitching sections toremove dust from the air.
Workers are suggested to wear fine mesh cloth dust
protectors.
The handles should be made of flexible polyethylenematerials, which even after prolonged and regular usegive a comfortable feel.
The blade guards of the cutting machines are to beredesigned. These guards can be designed either asenclosure guards or as interlocking guards. Enclosureguards will cover the entire blade. Interlocking guardswill allow the machine to function only after the blade
guards are lowered.
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AN ERGONOMIC LAYOUT OFCUTTING ROOM
CONCLUSION
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CONCLUSION During this project we came to know that ergonomics features
in the cutting rooms in most of the industries are very poor.
Our observation turns out that modern equipments and toolsare manufactured based on ergonomic designs andsuggestions.
But the cutting room work floor management and the building
layout do not support the concern of workers and ergonomics. These interventions made in the units would help to improve
the work environment of the garment manufacturing units.
This study demonstrates that there is ample room forergonomic improvements in the clothing industry.
We need to continue to identify problems and, moreimportantly, implement solutions to reduce the risk of injuries insituations where we know problems exist.
So, there is a huge scope of improvement in the field ofergonomics in apparel industry.
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REFERENCES
PDFS
Ergonomics In The Garment Manufacturing Industry
Ergonomics Awareness Training
Ergonomic Interventions To Improve Work EnvironmentIn Garment
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Thank you