Introduction

Challenges Facing the Industry Today:

Competition From Overseas Companies Shortage of Available Workers Annual Turnover Rates Ranging From

30% to Over 100%

Introduction
Challenges Facing the Industry Today
Learning Curves of Several Months to

Attain Needed Skill Levels for Many Jobs Difficulty in Applying Modern Automation Technologies to Fabrics Processing

Ergonomics
Improving Ergonomic Conditions Can

Improve Productivity and Safety Enhance Competitiveness

Reduce Worker Compensation Costs
Provide More Reliable Workforce May Include Allocating High Risk Jobs to Machines

Where Possible .

Injuries and Illnesses Among Textile and 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

Injuries and Illnesses Among Textile and Apparel Workers

49% of Workers Experience Pain in the

Neck Absenteeism Increases as Working Conditions Worsen Loss of Workers Due to Injuries or Turnover is Associated With Working Conditions

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

Static Postures and CTDs

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 - Why?
Visual Demands of the Work

Geometry of the Work Station

Inadequate Seating

Postural Stress and Lighting

Precise Stitching Tasks are Visually Demanding
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

Seating
Straight Backed Wooden or Metal Chairs are

Typical in the Industry Chairs Often Lack Cushioning Chairs Often Lack Adjustable Back Rests Chairs Often Lack Height Adjustability

PsychoSocial Considerations
Psychomotor Demands are High (Speed,

Accuracy, Coordination) Positive Attitudes Toward Work are Inversely Related to Increased Monotony and Fatigue Positive Attitudes Toward Work are Directly Related to Job Satisfaction

Work Organization
As Many as 100% of Piecework Operators in High

Manipulation Jobs Have Symptoms of CTDs Workers in Piecework are 4 Times as Likely to Develop Severe Disabilities as Hourly Workers Workers in Piecework are 9 Times as Likely to Develop Arthritic and Osteoarticular Disorders as Hourly Workers As Duration of Employment in Piecework Increases, So Does Severe Disabilities

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 - A Comprehensive Ergonomics Program

Training for Supervisors and Managers
Awareness Training for Employees Job Analyses and Implementation of

Controls Worker Involvement and Participation Medical Management

Recommended by National Institute of Occupational Safety and Health (NIOSH)

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

Automated Materials Handling

Eliminates Heavy Lifting by Operators or Bundle

Boys Uses Pre-Programmed Hanging Conveyor Moves Only One or a Few Work Pieces Per Hanger Computer Controlled - Movement Tracked by BarCoded Hangers and Series of Scanners Delivers Work to Queue Near Operator

Automated Materials Handling

Strong on Pre-Programmed Use But Weak on

Flexibility (Short Term Changes, etc.) Technology is Rapidly Improving Future Models Will Direct More Work to the Queues of the Most Productive Workers and Less to Slower Workers or Beginners

Modular Manufacturing Concept

Conventional Textile/Apparel Industries Use the

Progressive Bundle System - Each Operator is Assigned to a Single Operation In Modular Mfg. a Complete Garment is Produced in a Modular Cell Cells May Have 10 Operators and 20 Machines Operators Are Not Assigned to a Single Operation But Move Between Workstations

Modular Manufacturing Concept

Teams of Operators are Responsible for Work

Planning and Management, Product Quality, etc. Employees are Empowered - Boosts Morale A Variety of Motions are Used by Each Operator Reduces Risk for CTDs and Relieves Static Postures Can Be Reconfigured Rapidly, Providing Great Flexibility

Modular Manufacturing
Significantly Reduced Absenteeism
Necessitates Better Ergonomic Designs of

Workstations to Accommodate Different Operators Many Operations Converted to Standing Workstations Instead of Seated Workstations Employees Paid on a Group Incentive System