Need of ergonomics; problems; solutions

1. ERGONOMICS IN THE
SEWING ROOM
Submitted By :
Angel Sharma
Ashmita Jain
Mansi Jain
Riddhi Malviya
BFT VII
FINAL JURY
ASSIGNMENT
Mentored By:
Mr. Manoj Tiwari
Associate Professor

2. CONTENTS
Need of ergonomics
Ergonomic principles
Ergonimic problem identification and
solutions according to postures
Review of material handling systems

3. 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

4. INJURIES AND ILLNESSES AMONG
SEWING ROOM WORKERS
0
10
20
30
40
50
60
70
80
Back Pain Low Back Pain CTD(Cumulative trauma
disorder)
Neck pain
Percentage of workers suffering from
REFERENCE : National Institute for Occupational Safety and Health (NIOSH)
Elements of Ergonomics Programs, January 1997

5. 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

6. CLASSIFICATION OF TASKS
ACCORDING TO POSTURES:
SEWIN
G
ROOM
TASKS
SITTING
STITCHIN
G
HAND-
SEWING,
TRIMMING
GARMENT
ASSEMBL
Y 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

7. SEWING ROOM TASKS ASSOCIATED
WITH INJURIES AND ILLNESSES
• Pain in the Shoulders, Wrists, and Hands
Stitching Tasks
• Pain in all Upper LimbsHand Sewing and
Trimming
• Elbow Pain
Ironing by Hand
• CTDs of the Hands and Wrists
Garment 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%2520Point
s/Ergonomics%2520in%2520the%2520Textile%2520Industry.PPT+&cd=2&hl=en&ct=clnk&gl=in

8. 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

9. 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.

10. 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/

11. • 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 .

12. REFERENCE : http://ofslides.com/nagarajan23-140665/presentation-201653

13. THE WRONG WAY THE RIGHT WAY

14. 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
15

16. SOME WAYS OF PROPER VENTILATION
REFERENCE: http://elizabethgatlin.com/tips-and-tricks/natural-ventilation-tricks-to-cool-off-your-summer/

17. TABLE
PROBLEM
• 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

18. 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

19. •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/sewingsta
tiondesign.html

20. 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.

22. 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.

23. REFERENCE: http://www.sailrite.com/Light-for-Sewing-Machine-Power-Stand-Table#

24. 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

25. 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

26. TREADLE/PEDAL
PROBLEMS:
• 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

27. 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

28. OTHER HEALTH AND SAFETY
REQUIREMENTS

29. 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

30. 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

31. POTENTIAL HAZARDS
Employees 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.

32. 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

33. THANK YOU