Uneak White's Personal Brand Exploration Presentation
Ergonomics in apparel manufacturing
1. NIFT GANDHINAGAR
Assignment - 2
Ergonomics
Ajay Gayakwar, Bittu Singh, Komal Gajjar, Radhe Kumar, Shubham Singh –
DFT VII
11/20/2018
Ergonomic assessment of workstations in garment manufacturing
2. 1
Ergonomics Assessment and Improvisation suggestion for Garment manufacturing
Workstations
Environmental factors:
Environmental parameters such as temperature, noise intensity and
illumination level affect health of the workers. It was noted that the average
minimum and maximum temperature in all the selected areas was recorded
as 20 °C and 35 °C. Average minimum and maximum noise levels are 72dB-
87dB.
- Lighting
- Vibration
- Eye Strain
Products :
Shirt, Jackets, Trousers
Psychosocial Factors: (these will be more difficult to find out, but in case you can
find any, kindly point out )
3. 2
Contents
1. Operation: Manual Marker Making.......................................................................3
2. Operation: Sewing..................................................................................................9
3. Operation: End Line Inspection............................................................................20
4. Operation: Trimming...........................................................................................26
5. Operation: Ironing ................................................................................................31
6. Workstation: Spreading and Cutting ....................................................................37
4. 3
1. Operation: Manual Marker Making
Posture
Standing posture: The maximum reach envelope for the standing position
was significantly greater than sitting position.
And, It’s main requirement of manual marker making
Weight/load
Lightweight
Gripping
Contact stresses
Lifting. lowering, carrying
High
Force/exertion
Repetitive motion
Magnitude/size
Duration
Force/Exertion
Tool design
1. Posture Analysis
Ergonomic assessment for operator marking patterns on fabric manually
5. 4
Tool used – RULA - Rapid Upper Limb Assessment (RULA) is a survey method
developed for use in ergonomic investigations of workplaces where work related
upper limb disorders are reported. RULA is a screening tool that assesses
biomechanical and postural loading on the whole body with particular attention to
the neck, trunk and upper limbs. Reliability studies have been conducted using RULA
on groups of VDU users and sewing machine operators. A RULA assessment requires
little time to complete and the scoring generates an action list which indicated the
level of intervention required to reduce the risks of injury due to physical loading on
the operator. RULA is intended to be used as part of a broader ergonomic study.
10. 9
2. Perceived causes of the posture adopted
3. Probable MSD’s that may be caused by standing posture
4. Probable causes of the problematic postures
5. Improvements suggestions
- Standing surface: Provide fatigue mate as the operator is working
in the standing posture. It will reduce the fatigue and increase the
productivity.
- Table height should be slightly below the elbow level for standing
working positions.
6. Comments on the cost implications if improvements are made.
7. Probable impact on productivity
2. Operation: Sewing
Observation
It is required to have a good understanding of working environment, procedures,
processes and issues related to musculoskeletal disorders. These may include
11. 10
interviews, focus group discussions, and sessions with workers, photographs and
video recordings. As a first step, interviews and discussion sessions were carried out,
and helped in the selection of tasks for further data collection and also provided
workers’ opinions about the potential causes of workplace risk. Then the selected
activities, workstations and workers were observed performing their normal
activities. Initial feedback provided by workers highlighted that those who
performed their work in sitting positions complained about pain in the neck and
back; whereas those who were working in a standing posture for a long time,
complained of leg, trunk and foot pain. It was further mentioned and observed that
injuries to fingers are a very common problem overall at the workplace.
Data collection
It was carried out by photographs and video recording selected workers on selected
workstations for specific tasks. Workers were briefed about the purpose of study
and requested to perform their work normally. Selection of the appropriate
recording angle and position was important in this case; click the images or
recording video from appropriate angles so that the positions and movements of
different body parts could be captured.
Problem
In the factory there was problem in different operation in different department like:
- Sewing in line, Garment inspection, ironing, thread cutting, spreading etc. we are
observing the problems in the sewing line during the stitching of garment, when
picked piece from side or attaching of button at that time the neck and body posture
are bend toward the machine or side.
Thought process
Its involved the use of selected snap-shots were used to carry out further data
analysis, where REBA coding scheme was used to assess the level of risk attached to
the adopted working strategy and body posture. In the Table 1 defines the level of
risk, with REBA scores and appropriate actions required to reduce the level of risk. It
is clear from the table if the final REBA score is greater than 11, there is a very high
level of risk and an immediate change in working strategy and posture is required.
Similarly, REBA score in between 8-10, shows high risk and demands investigation
and implementation of change in working posture – further categories and their
respective REBA scores and actions required, are in table 1. And in the table 2 the
defined level of risk, it is clear from the table if the final RULA score greater than 7,
there is very investigation and change are required immediately. So it is require to
change their position or work station.
12. 11
TABLE 1: REBA LEVEL ACTION TABLE
TABLE 2: RULA LEVEL ACTION TABLE
Data analysis
It was carried out on the data collected in the form of still frames and videos. There
were performing tasks have been selected for the final REBA risk assessment
analysis. Figures1 and 2 show the adopted working strategies and body postures.
Figure 1: Operator attach button in the garment Figure 2: Operator pick the piece
Result
After the use of ErgoFellow software final result come out score is 9 for REBA and
RULA score is 7 which is very high investigation and change are require immediately.
So, work will be carried out on investigating the major causes of risk attached with
different postures by analysing the postures falling into action categories 3. This will
help in understanding, what are the major causes of musculoskeletal disorders in the
garment industry work and how these can be avoided with the help of better
workplace design and working strategies.
13. 12
Suggestions
Providing same level of table for picking the pieces of garment.
Providing the height of chair with proportion to height of machine where
fabric is put for stitch.
Conclusion
Bad working postures, poor working strategies and inadequate workplace design are
the major of work-related musculoskeletal disorders WMSDs at work. This is the
causes of WMSDs in the garment manufacturing industry and the REBA and RULA
method was used to investigate the level of risk attached with the postures adopted
by different workers. A significant number of workers performed their work in a bad
way and there is a need to change working strategies so that a safe and healthy
working environment can be maintained.
These are the screenshots of process result of REBA.
23. 22
11/22/201
8 ErgoPlus Platform
Trunk
Position 0 - 20 degrees
Adjustments
Score 2
Legs
Position Bilateral weight bearing
Adjustments
Score 1
Force Load
Position < 11 lbs.
Adjustments
Score 0
Upper Arm
Position 45 - 90 degrees
24. 23
Adjustments
Score 3
Lower Arm
Position 60 - 100 degrees
Adjustments
Score
Wrist
Position 15 - 15 degrees
Adjustments Wrist bent from midline
Score 2
Risk
Risk Index
1
.
2
5
https://industrial.ergo-
plus.com/ergonomics/job-task/6015d8fd-
ee22-11e8-bab9-0614ac2ade64/report 2
25. 24
Assessment Results
REBA Score 5.00
Task Variables
Neck
Position 20+ degrees
Adjustments
Score 2
Trunk
Position 0 - 20 degrees
Adjustments
Score 2
Legs
Position Bilateral weight bearing
Adjustments
Score 1
26. 25
Force Load
Position < 11 lbs.
Adjustments
Score 0
Upper Arm
Position 45 - 90 degrees
Adjustments
Score 3
Lower Arm
Position 60 - 100 degrees
ErgoPlus Platform
Adjustments
Score
Wrist
Position 15 - 15 degrees
27. 26
Adjustments Wrist bent from midline
Score 2
Conclusion
REBA action level
Action Level REBA Score Risk Level Action
0 1 Negligible None necessary
1 2-3 Low May be necessar
2 4-7 Medium Necessary
3 8-10 High Necessary soon
4 11-15 Very High Necessary now
The REBA score is 5.0, which falls in action level 2 group. According to the above
table the risk level of working in this posture is medium and it action needed to
reduce risk is necessary.
4. Operation: Trimming
Posture
Standing posture: The maximum reach envelope for the standing position
was significantly greater than sitting position.
And, It’s main requirement in marker making
Weight/load
Lightweight
Gripping
Pinch grip
Contact stresses
Carrying of the garment is frequent activity
High
Force/exertion
Force is higher
Repetitive motion
32. 31
2. Probable MSD’s that may be caused by standing posture
3. Probable causes of the problematic postures
4. Suggested Improvements
Trimmer can be tied to the table
Standing surface: Provide anti-fatigue mate as the operator is working in the
standing posture. It will reduce the fatigue and increase the productivity.
Table height should be slightly below the elbow level for standing working
positions.
Provide foot platform for short worker to ensure appropriate work height.
Attaching spring to the iron so operator doesn’t need to keep the iron at its
place after the pressing cycle.
5. Impact on productivity/ gender neutrality/ age neutrality etc.
6. Suggestions
5. Operation: Ironing
Posture and Work study
Standing posture: The maximum reach envelope for the standing position was
significantly. Weight carries by the operator is lesser than 5 kg. Iron handled by
power grip. Sometimes hand of operator twist for some operations house tip of the
iron to reach some areas of the garment. Feting iron every time and keep it to it’s
place again and again causes wasted repeated actions.
1. Posture Analysis
Ergonomic assessment for ironing operator
33. 32
Tool used – QEC - The quick exposure checklist (QEC) quickly assesses the exposure
to risks for work related musculoskeletal disorders (WMSDs). QEC is based on the
practitioners’ needs and research on major WMSD risk factors. About 150
practitioners have tested QEC and modified and validated it using both simulated
and real tasks. QEC has a high level of sensitivity and usability and largely acceptable
inter-and intra-observer reliability. Field studies confirm that QEC is applicable for a
wide range of tasks. With a short training period and some practice, assessment can
normally be completed quickly for each task.
35. 34
Tool used – Discomfort questionnaire – It is very useful to know which parts of the
body the workers most feel discomfort. This information is very important to make
changes in the work.
37. 36
Tool used – OWAS - The use of OWAS method has been classified by categories of
knowledge, by country and by year. The search was made by selecting only the main
collection of the Web of Science. This was selected by the option “Advanced search”
using the term OWAS (ts=OWAS) for the time period of 1900 to 2017. A total of 166
results were found, consisting of conference papers and articles in scientific journals.
In conclusion, the OWAS has been applied mainly in two sectors: “Manufacturing
industries” and “Healthcare and Social assistance activities”. This method needs to
be complemented with other indirect or direct methods. Also, whenever the OWAS
has been used, whether individually or together with other methods,
musculoskeletal disorders risks have been detected, this perhaps being an indicator
to review the evaluation parameters because overestimating the risk.
2. Perceived causes of the posture adopted
3. Probable MSD’s that may be caused by standing posture
- muscular strain
- upper limb disorder
4. Probable causes of the problematic postures
- Repetitively fetching for the iron can cause muscular strain
5. Suggested Improvements
- Position the press perpendicular to overhead lights or use multiple
38. 37
light sources to improve visibility.
- Placing of materials, tools and controls where they can be reached
easily by the worker without bending or twisting the body
- Iron can be hanged on front side which will result in less wasted
motion to reach the iron every time.
- Repetitiveness of the task can be decrease by eliminating iron
resting place at one side of the table.
- Standing surface: Provide anti-fatigue mate as the operator is
working in the standing posture. It will reduce the fatigue and
increase the productivity.
- Table height should be slightly below the elbow level for standing
working positions.
- Provide foot platform for short worker to ensure appropriate
work height.
- Attaching spring to the iron so operator doesn’t need to keep the
iron at its place after the pressing cycle.
6. Comments on the cost implications if improvements are made.
7. Probable impact on productivity/ gender neutrality/ age neutrality etc.
6. Workstation: Spreading and Cutting
ERGONOMICS AWARENESS CHECKLIST
PRIORITY TASK HOW HARD? HOW
OFTEN?
SCORE
5 SPREADING
FABRIC
5 4 20
5 CUTTING FABRIC 5 4 20
3 LOADING OF
FABRIC
3 4 12
2 STACKING CUT
PIECES
2 4 8
Priority: 5: more and 1: less
HOW HARD IS THIS TASK? SCORE
VERY EASY 1
EASY 2
SOMEWHAT HARD 3
HARD 4
VERY HARD 5
HOW OFTEN IS THIS TASK DONE? SCORE
A FEW TIMES A YEAR 1
A FEW TIMES A SHIFT OR WEEK 2
39. 38
UPTO 4 HRS PER SHIFT 3
MORE THAN 4 HRS PER SHIFT 4
MORE THAN 8 HRS PER SHIFT 5
CONTRIBUTING FACTORS
Awkward postures
Visual efforts (eye strain/fatigue)
Repetitive motion
Forceful exertion
Pressure points
Vibrations (cutting machine)
EXPLANATION OF WORKSTATION FROM ERGONOMICS POINT OF VIEW
SITTING/STANDING: The workstation is a standing workstation where the
worker stands on the ground. There is no foot rail or foot rest given. Leg and
feet have sufficient workspace below the work station. This leads to static
neck postures.
Arm rest: there is no arm rest that is given to the operator.
Lighting: lighting in the workstation is sufficient.
Body posture(head, neck, trunk): the operator need to tilt forward and bend
his/her neck every time he/she is matching the lines with the pieces. The
head and neck face forward while doing the operation, be it spreading,
cutting or stacking finished pieces.
Body postures(arms and shoulders): Fabric loading is done manually with the
help of hands. While spreading the hands are completely stretched and while
cutting the fabric, pressure points needed to be kept in mind.
Environment: the relative humidity of the air is maintained between 30% and
60%, during the season, company has maintained the ambient indoor
temperature between 68°F and 74°F. During Cold season, the recommended
temperature is between 73°F and 78°F.
PROBLEMS AND SOLUTIONS
LOADING OF FABRIC
PROBLEM
Bolts of fabric lifted by hand are very heavy and create a substantial risk of
lower back injury.
SOLUTION
Limiting the weight of the bolt.
Using 2 people to lift the bolt.
40. 39
Using the turntable on the spreader to assist with lifting one end of the bolt
at a time.
Using hand made bolt stands to assist with lifting to a tail spreader.
SPREADING THE FABRIC
PROBLEMS
Long reaches are required to cut across the width of the fabric each time a
layer Is completed or flaws are removed from the fabric.
SOLUTIONS
Use 2 people, one on each side of the table, who cut towards each other. This
reduces a lot of reaching and poor postures when cutting across the width of
the fabric.
CUTTING THE FABRIC
PROBLEMS (ELECTRIC SAWS)
Excessive reaching with shoulders and back.
Poor wrist postures.
Hand or arm vibration and contact pressure on the hand when stapling the
pattern to the fabric or perforating the layers of fabric.
Extreme pressure required when cutting with a electric saw.
SOLUTIONS
Improve shoulder and back posture by setting the table and saw at a good
working height for the operator.
Extend the handle and cut from both sides of the table to reduce excessive
reaching.
Avoid poor wrist posture with an adjustable angle handle.
Maintain saws and use a vibration dampening handle to reduce the amount
of vibration.
The best weights for holding down the patterns are small and have handles
on the top. Clamps are also good for holding the fabric in space.
A pattern tacker is good for stapling the pattern to the fabric, it can be
manipulated with one hand and causes less contact stress on the hand than
an office type stapler.
Adhesive spray can be used to attach the pattern to the fabric.
A good waste disposal method is to use a garbage pail firmly attached to
dolly.
Place anti-fatigue mats, the length of the table to reduce foot and leg fatigue.
Follow other good safety practices such as properly adjusted guards, chain-
mail gloves for straight-blade saw operators, and regular maintenance on the
41. 40
blade to ensure it is sharp and lubricated to minimize the force required to
push it through the fabric.
STACKING CUT PIECES
PROBLEMS
Piling cut fabric on to the floor requires a stooped posture. Sometimes cut
pieces are piled underneath the cutting/spreading table.
SOLUTION
Use of carts instead of storing underneath the table or onto the floor.
The best carts for this job have one shelf that is at the same height as the
cutting table. The cut pieces can be slid off the table directly onto the cart
with very little lifting by the operator.
Carts with multiple shelves located close together are also good. This
minimizes the operator’s range of lifting.
Another type of cart has three shelves. Only the top two are used and middle
shelf slides out from either side to allow easier access to it.
FLOOR SURFACE
PROBLEM
Operators stand for extended period of time on hard surfaces. Concrete
floors can lead to fatigue in the legs, feet and back. Often no seating option
or footrests are provided.
SOLUTION
Provide standing operators with good quality anti-fatigue mats that cover the
entire working area.
Provide operators with a footrest and a sit-stand stool to help relive the
stress on the feet, legs and back.
Allow operators to rotate between sitting and standing work positions.
Compression stocking can be used.
AISLE SPACING
Aisle spacing for the cutting/spreading activity meets the ergonomic standard
at company.
Secondary aisle spacing is 3 feet and primary aisle spacing is 5 feet
