ERGONOMICS IN THE SEWING ROOM
Submitted By : Angel SharmaAshmita JainMansi JainRiddhi MalviyaBFT VII
FINAL JURY ASSIGNMENT
Mentored By: Mr. Manoj TiwariAssociate Professor
CONTENTS
Need of ergonomics
Ergonomic principles
Ergonimic problem identification and solutions according to postures
Review of material handling systems
NEED OF ERGONOMICS IN THE SEWING ROOM
Can improve productivity and safety - enhance competitiveness
Provide more reliable workforce
Loss of workers due to injuries or absenteeism is associated with working conditions
REFERENCE : http://ofslides.com/nagarajan23-140665/presentation-201653
INJURIES AND ILLNESSES AMONG SEWING ROOM WORKERS
Back Pain Low Back Pain CTD(Cumulative trauma disorder)
Neck pain0
10
20
30
40
50
60
70
80Percentage of workers suffering from
REFERENCE : National Institute for Occupational Safety and Health (NIOSH)Elements of Ergonomics Programs, January 1997
SOME FUNDAMENTAL ERGONOMIC PRINCIPLES TO KEEP IN MIND :
1.Use proper tools
2.Keep repetitive motions to minimum.
3. Avoid awkward positions
4. Get proper rest
REFERENCE: http://www.iapa.ca/pdf/ergonomics_handbook.pdf
CLASSIFICATION OF TASKS ACCORDING TO POSTURES:
SEWING
ROOM TASKS
SITTINGSTITCHIN
G
HAND-SEWING,
TRIMMING
GARMENT ASSEMBLY
TASKS
SPECIAL CASE: FOOT
OPERATED SEWING
STANDING
INSPECTION
IRONING BY HAND
TABLE OPERATION
S
MOVEMENT
MATERIAL HANDLING
REFERENCE :http://webcache.googleusercontent.com/search?q=cache:PjAGX8ElhVEJ:www.toolboxtopics.com/Beyond%2520Safety%2520Meetings/Power%2520Points/Ergonomics%2520in%2520the%2520Textile%2520Industry.PPT+&cd=2&hl=en&ct=clnk&gl=in
SEWING ROOM TASKS ASSOCIATED WITH INJURIES AND ILLNESSES
• Pain in the Shoulders, Wrists, and HandsStitching Tasks
• Pain in all Upper LimbsHand Sewing and Trimming
• Elbow PainIroning by Hand
• CTDs of the Hands and WristsGarment Assembly Tasks
• Pain in the Back Foot Operated Sewing
• Back pain and knee painInspection and table operations
REFERENCE :http://webcache.googleusercontent.com/search?q=cache:PjAGX8ElhVEJ:www.toolboxtopics.com/Beyond%2520Safety%2520Meetings/Power%2520Points/Ergonomics%2520in%2520the%2520Textile%2520Industry.PPT+&cd=2&hl=en&ct=clnk&gl=in
STATIC POSTURES• Analysis reveals that 40% of operators at sewing
machines stoop forward > 20o throughout the machine cycle• 60% tilt their heads forward > 20o throughout
the machine cycle• Visual demands of the work• Geometry of the work station• Inadequate seating
1. SITTING TASKS:STITCHING, HAND SEWING, GARMENT ASSEMBLY
REFERENCE : http://ofslides.com/nagarajan23-140665/presentation-201653
MAJOR CONCERN FOR SITTING TASKS:SEATING
• Stools are typical in the industry. They often lack cushioning, back rests and height adjustability.• Employees must sit for long periods in the same position, resulting in soreness of the back, neck, buttocks, and reduced circulation to the legs.
SOLUTIONS
Chairs should have:• Easily adjustable height and backrest
position.• Padded back rest with rounded edges
that supports worker's lower back.• No wheels, or wheels that lock.• A cushioned seat, which distributes the
worker's weight so no body part gets all the pressure.
• Swivel motion, so that worker does not have to twist to reach the side or behind
REFERENCE: http://www.sewingreviews.org/ergonomic-sewing-tips/
• To choose a proper chair, consider the amount of movement the task requires, and the size of the worker.
• Chairs should be placed at an appropriate distance from the workstation, so workers can perform tasks without pulling their elbows away from the body .
REFERENCE : http://ofslides.com/nagarajan23-140665/presentation-201653
THE WRONG WAY THE RIGHT WAY
DURATION OF EXPOSURE
• Machine operators experience cumulative damage to the neck and shoulders over time• Risk for persistent neck and shoulder pain
increases with years of employment as a machine operator• Work for more than eight years as machine
operator increases risks for neck and shoulder pain• Solutions :• Frequent rest periods• Job rotations• 2 minutes exercises to reduce fatigue
REFERENCE: http://www.sewingreviews.org/ergonomic-sewing-tips/
15
VENTILATION
• Since a lot of machines are continuously working in the sewing room and the number of workers is very high too, it tends to get very stuffy and suffocating• To combat this problem, ensure:• Proper cross ventilation through adequate and properly
placed windows• Presence of exhaust fans on the walls
SOME WAYS OF PROPER VENTILATION
REFERENCE: http://elizabethgatlin.com/tips-and-tricks/natural-ventilation-tricks-to-cool-off-your-summer/
TABLEPROBLEM• Workers maintain awkward shoulder, elbow, and
wrist postures while sewing because of improper table height.
REFERENCE : http://www.wsps.ca/WSPS/media/Site/Resources/Downloads/ergonomics_handbook.pdf?ext=.pdf
SOLUTIONS:
• Provide height adjustable tables.• Tables should be adjusted so the work is at elbow height
and wrists are kept straight . • Postures due to improper table height tires the neck,
shoulder, and upper back muscles and may result in muscle pain.
REFERENCE: https://www.osha.gov/SLTC/etools/sewing/sewingstationdesign.html
•For sit-down work, the table should also be high enough to allow room underneath for the worker's legs. The table top should not press on the worker's thighs. Workers who use a treadle need more room than those who don't so they can move their legs more easily.
•Edges of work surfaces should be padded or rounded, so workers can rest their arms against them.
REFERENCE: https://www.osha.gov/SLTC/etools/sewing/sewingstationdesign.html
TILT-ABLE
ADVANTAGES:• Pain-free sewing• Provides better view of sewing work
area• Allows sewer to keep back straight
for less back pain• Perfect for sewers with Bi/Tri-focal
glasses
Tables may be tilted slightly toward workers, to enable them to see the work more easily and to reduce awkward wrist postures.
LIGHTING Use adjustable task lighting to make it easier for the worker
to see product during set up . Ensure bulbs are replaced frequently so they are functional at
all times. Required illumination level in sewing room is 500 lux.
REFERENCE: http://www.sailrite.com/Light-for-Sewing-Machine-Power-Stand-Table#
POSTURAL STRESS AND LIGHTING• Thread and fabric often offer little or no visual contrast• 36% of operators feel lighting is inadequate• Surveys found light levels at less than 60% of
recommended levels • Operators lean forward to see their work
2. STANDING TASKS:INSPECTION , IRONING BY HAND
REFERENCE: https://www.osha.gov/SLTC/etools/sewing/sewingstationdesign.html
SOLUTIONS
• Provide sit/stand workstations, which encourage changing posture.• Provide anti-fatigue mats for workers who are
standing for prolonged periods. Anti-fatigue mats promote better circulation and reduce fatigue in the lower extremities.
REFERENCE: https://www.osha.gov/SLTC/etools/sewing/sewingstationdesign.html
TREADLE/PEDALPROBLEMS:• Employees operating a treadle for prolonged periods must
maintain awkward and unbalanced posture.• Employees required to apply a constant treadle force must
maintain static lower extremity postures.• Workers may also maintain poor posture if treadle is too close or
too far away
3. SPECIAL CASE OF SITTING WORK: FOOT OPERATED SEWING
REFERENCE: https://www.osha.gov/SLTC/etools/sewing/sewingstationdesign.html
SOLUTIONS:• Use job/task rotation through tasks that do not
require constant leg pressure and awkward leg posture.• Distance of the operator from the machine should
ideally be such that he can maintain a 90 degree angle while bending the leg
REFERENCE: https://www.osha.gov/SLTC/etools/sewing/sewingstationdesign.html
OTHER HEALTH AND SAFETY REQUIREMENTS
SPACE REQUIREMENTS
Provide adequate area to the workers • At least 0.5 m x 0.5 m area while sitting
Proper aisle space• If trolleys of dimensions 1m x 1m are to be
used to transfer material, aisle space should be 1.5m
MATERIAL HANDLING• Employees may sometimes have to move large
bundles of cut fabric from delivery, or between stations.• Eliminates Heavy Lifting by Operators or “Bundle
Boys”• Use trolleys with proper height and wheels so that
the stress on helper boys is limited
POTENTIAL HAZARDSEmployees repeatedly bend at the waist and reach into transportation tubs to load or retrieve cut fabric, causing stress on the back and arms.
Employees repeatedly bend to lift bins or bundles of fabric.
Employees lift bins or bundles over chest height, which may cause injury to the shoulders and back.
Force applied while pushing or pulling carts containing fabric pieces may cause injury to the arms and back.• Thread and scraps of material may clog the wheels, causing the worker to apply more force when pushing or pulling carts.
POSSIBLE SOLUTIONS
Use height-adjustable carts to reduce the need to bend or reach into the carts.
Design stations to allow most lifts at waist level.Use bins with good handles to make lifting easier
THANK YOU
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