ergonomics in the sewing room

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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

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Page 1: ERGONOMICS IN THE SEWING ROOM

ERGONOMICS IN THE SEWING ROOM

Submitted By : Angel SharmaAshmita JainMansi JainRiddhi MalviyaBFT VII

FINAL JURY ASSIGNMENT

Mentored By: Mr. Manoj TiwariAssociate Professor

Page 2: ERGONOMICS IN THE SEWING ROOM

CONTENTS

Need of ergonomics

Ergonomic principles

Ergonimic problem identification and solutions according to postures

Review of material handling systems

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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

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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

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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

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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

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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

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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

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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.

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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/

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• 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 .

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

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THE WRONG WAY THE RIGHT WAY

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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/

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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

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SOME WAYS OF PROPER VENTILATION

REFERENCE: http://elizabethgatlin.com/tips-and-tricks/natural-ventilation-tricks-to-cool-off-your-summer/

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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

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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

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•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

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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. 

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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.

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

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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

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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

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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

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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

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OTHER HEALTH AND SAFETY REQUIREMENTS

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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

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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

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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.

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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

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THANK YOU