ERGONOMICS

IMPLEMENTATION
Presented By:Abinash Mohanty
Anurag Singh
Avinash Kumar
Shashi Paswan
Vipin Kushwaha
DFT-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

Limiting the weight of the bolt

hand are very heavy and create a

Use fork lifters to lift the bolt

substantial risk of low back injury.

Poor Posture during placing the Spreader

Use bolt stand to keep the fabric bolt in

bar in fabric bolt

sloped position

Extreme postures during fabric cutting-

Improve shoulder and back posture by

Excessive reaching with shoulders and

setting the appropriate height of table and

back. Poor wrist postures and Hand or arm

cutter according to worker

vibration and contact pressure on the hand

Extend the handle and cut from both sides

when stapling the pattern to the fabric or

of the table to reduce excessive reaching.

perforating the layers of fabric.

Placing spreader bar in the bolt

of fabric

Extreme postures required when

cutting with an electric cutter

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

Ergonomically designed scissors and

trimming.

cutting equipment help reduce contact

Scissor handles are narrow and create

stresses.

contact stresses.

They also offer comfortable cutting posture

Scissors are dull and require excessive

and lesser force.

force to operate.

Working in a standing position on a regular Use Anti-fatigue mats

basis can cause sore feet, swelling of the

Anti-fatigue mats promote better

legs, muscular fatigue, low back pain,

circulation and reduce fatigue in

stiffness in the neck and shoulders, and

the lower extremities.

other health problems.

Scissors in use.

Workers standing position

Ergonomically designed scissors

Anti fatigue mats

Problems/Solutions in Sewing
Section

Problem

Solution

Chairs have no height

adjustable 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 to

work with the elbows down, close
to the body.
Employees should have to reach
no farther than 18 inches to the
front.
Employees should be able to rest
their arms, but not against sharp
edges.
Employees should not have to
twist or bend to pick up or put
down objects.

Stools used by workers.

Sewing table in use

Ergonomic Chairs.

The sewing table designed ergonomically

Contd
Problem

Solution

With no table height adjustment

Table edges should be padded or

options the worker had to maintain

rounded to enhance the blood

awkward postures

circulation

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.

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 workrelated musculoskeletal disorders.

Contd
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
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?

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.

Hands and fingers of

the sewing operators
get stiff due to
inflammation in the
median nerve, caused
by repetitive actions.

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

Work Enhancements
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