Industrial Engineering

Ergonomics

Submitted to: Submitted by:

Arivoli .N Shalu kumarI
Assistant professor BFT/18/356
Department of fashion technology.
 Acknowledgement

I would like to express our special thanks of gratitude to my

“Industrial Engineering” faculty Mr. Arivoli.N for his able guidance
and support in this assignment.

I would also like to thank NIFT Bengaluru for providing me all the
resources that were required.

-Shalu kumari
 Ergonomics
Ergonomics is a topic that affects us all, yet few of us have a good understanding of what
the term actually mean or realize how it affects us.

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. The opposite of this, what typically happens
in the workplace, is that a worker is forced to work within the confines of the job or
workstation that is already in place. This may require employees to work in awkward
postures, perform the same motion over and over again or lift heavy loads-all of which
could cause work related musculoskeletal disorders(WMSD).

These injuries often start as minor aches and pains but can develop into disabling injuries
that affects our activities of daily living such as laundry and even the ability to pick up our
children.

Ergonomics aims at preventing injuries by controlling the risk factors such as force,
repetition posture and vibration that can cause injuries to develop. Some fundamental
ergonomics principles that should be followed in our workplaces are:

• Use proper tools.

• Keep repetitive motions to minimum.
• Avoid awkward postures.
• Use safe lifting procedures.
• Get proper rest.
 1.Cutting
The primary task in the cutting department are:

• Loading the spreading machine.

• Spreading the fabric.
• Cutting the fabric.
• Stacking the cut pieces.

Measures to be taken in the cutting operation:

Loading the spreading machine:

• Spreader loaded with fixed assist accompanying the spreader.

• Ramp for loading the spreader- from ergonomic point of view using ramps for
loading spreader is the best technique.

Spreading the fabric

• Use of fabric catcher to eliminate the need the need for the operator to pick up and
manipulate weights to hold the fabric in place.
• Table and platform should be at appropriate heights for the operator, and the
operator has something to lean on to support his or her upper body weight while
smoothening the fabric.

Cutting the fabric

Band saw

• The table should be at an appropriate height and the operator should be able to
reach the blade without fully extending his/her arm and leaning forward.

Die cutters

• A good height for the cutting surface is several inches below elbow height.
• The input and the deposit surfaces should be at similar heights and easilyaccesible.

Ergonomically designed scissors and cutting equipment should be used as it reduce

contact and stress. They also offer comfortable cutting posture and lesser force.
 • The best location for controls is directly in front of the operator, at approximately
elbow height.
• The die can be located under the fabric. This is a good technique for large, heavy dies
so they do not have to be picked up each other a new section of fabric is cut.
• A raised platform can be used to bring the operator to a good height.

Electric saws

• Maintain saws and use a vibration dampening handle to reduce the amount of
vibration.
• Extend the handle and cut from both sides to reduce excessive reaching.
• The best way foe holding down the pattern are small and have handles on the top.
Clamps are also good for holding fabric in place.
• Place anti-fatigue mats under the table to reduce foot and leg fatigue.

Automatic cutters

• The out feed table should also be adjustable in height to meet the requirements of
each operator.
• Locate waste bins at the end of the table, running the entire width of the table and
providing space for feet underneath.

Stacking the cut pieces

• 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
things by the operator.
• Carts with multiple shelves located close together are also good. This minimizes the
operator’s range of lifting.

Standing posture

• Provide sit/stand workstations which encourages changing positions.

• Tables may be tilted slightly toward the worker, to enable them to see the work
more easily and to reduce awkward wrist postures.
• Using foot rest, can take stress off a worker’s back and legs.
• Provide height and tilted adjustable tables; tables should be set at elbow height.
• Allow operator to rotate between sitting and standing work postures.
• Institute job rotation through tasks that do not require bending at the waist and
cutting
 • cutting table length depend on the size of the room and the width should be
maximum 120cm(4 ft) maximum width of the fabric.

Suggestion to improve work environment

• Height-adjustable wooden platform is suggested as an adjunct to the cutting table

for adjusting the work height for various operations. The wooden platform will also
help in preventing electrical shocks while operating electrical instruments.
• The inspection table should have a forward inclination towards the worker to enable
the workers to have a clean view of the fabric being examined and to maintain
postural stability while at work.
• The table top can be covered with a rough cloth to prevent slipping of the fabric,
• A minimum lightning level of 400 lx is recommended .
• Provision of local exhaust ventilation that uses suction, based on the principle of
vaccum cleaner, is to be encouraged in the cutting and stitching sections to remove
dust from the air.
• The blade guards of the cutting machine are to be redesigned. These guards can be
designed either as enclosure guards or as interlocking guards. Enclosure guards will
cover the entire blade. Interlocking guards will allow the machine to function only
after the blade guards are lowered. Tools like shears used for fabric cutting need to
be redesigned. The handle should be made of flexible polyethylene materials, which
even after prolong and regular use give a comfort feel.
Hand postures

• Institute job rotation through tasks that do not require cutting with scissors.
• Reduce the amount of force needed to operate tools by keeping tools well
maintained(oiled and cleaned).
• Instituting a tool sharpening program.
• Adhesives can be used to stick the pattern to the fabric for easy cutting.
• Use of vibration dampening tools to reduce vibration during cutting.

Light intensity

The given range of light intensity should be present in the cutting room (950-1050 lux).

For alternate standing and sitting Provide standing workers with chairs or
posture when doing the same or the stools so that they may sit occasionally.
similar tasks at a work table, a high stool
with a good footrest is useful.

Low cost metal clamps keep the fabric firm and

stable, allow easier and faster cutting operation.
The above picture shows the ergonomically designed cutting workstation in the textile
industry. Cutting process is a standing operation and so the operator need to be
comfortable while performing it.

The improvements done in the above workstation are as follows:

• Anti-fatigue mats should be used to reduce the strain in legs.

• For the continuous operation of cutting, foot rest can be used to make worker more
comfortable and reduce the fatigue and strain in legs and back.
• There should be enough leg space between the table and the worker standing
minimum of 15 cm.
• It is always advisable to use height-adjustable tables in the industry so that it can be
altered accordingly with the worker’s height.
• Slippery coatings on work surface (ultra-high molecular weight polyethylene) can
reduce the force necessary to slide material l(fabric).
• Use of Treadle that eliminates awkward leg posture and requires minimal force to
operate, especially while standing.
• When feasible, use hip switches or redesigned foot treadles to eliminate the need to
apply constant standing pressure.
• Use electric, pneumatic, or otherwise partially automated tools.
 2.Sewing
Employees encounter several risk factors at sewing workstations, such as awkward arm,
trunk and leg postures. These postures are influenced by the size of the worker and design
of the following units of workstations:

• Chair.
• Table.
• Treadle/pedal.

Sewing involves taking cut materials, placing it on the sewing mount, then running itbthrouh
a running machine. This operation may require pinch grips and awkward arm, neck, and
trunk postures. Force may also be required to push fabric through the machine.some of the
common risk and possible solutions associated with sewing are listed below:

• Moving material to/from workstation.

• Setting up material.
• Manipulating material.
• Stitching material.

Moving material to/from workstation

Minimize overhead reach by:

• Lowering the rack or placing the station on platform or using height-adjustable

portable clothing racks or tables.

Minimize reaches to the side or behind associated with picking up new product or placing
complete fabric by :

• Placing fabric/bins closure to the worker.

• Placing fabric/bins at table height.
• Using height-adjustable fabric container;
• Adding an extension to work table;
• Using an automated or conveyor system that transport the fabric directly to and
from the worker.
• Use swivel chairs, which allow worker to turn to get bundles and pieces , rather than
twisting to reach to the side or behind. Swivelling can also make it easier for workers
to sit down and getup from workstations.
Setting up material

• Use automatic feeding and setup, which eliminate the operator using awkward
postures.
• Provide proper lightning.
• Using adjustable task lightning to make it easier for the worker to see product during
setup.
• Ensure bulbs are replaced frequently so they are functional at all times.
• Provide properly positioned general overhead lightning.

Manipulating material

• Use friction-increasing aids on fingers to reduce amount of force exerted in the pinch
grip.
• Analyze task to determine force requirement and use job/task rotation through task
not requiring pinch grip.

Stitching material

• Using height adjustable tables, which, when properly adjusted may reduce and
bending at the waist.
• Allow the machine to pull the fabric through rather than having the operator push
the fabric.
• Reduce the distance between the operator and the machine.
• The light intensity of minimum 800-1000lux should be maintained in the sewing
room.
 Sitting posture for sewing operation

Following measures should be taken to have ergonomically designed workstation for sewing
operation:

• Use of adjustable-Task light with “goose- neck” to make it easier for the worker to
see product during set up.
• Sewing table with an extension to hold unfinished garments.
• Use of friction-increasing aids on fingers to reduce amount of force exerted in the
pinch grip.
• Provide properly positioned general overhead lightning.
• Use height-adjustable 5 foot swivel chairs, which allow worker to turn to get
bundles and pieces, rather than twisting to reach to the side or behind. It also helps
the workers to sit down and getup from the workstation.
▪ Padded back rest with rounded edges that supports worker’s lower back.
▪ A gently sloped or "waterfall” front edge from pressing into the back of the
legs.
▪ A cushioned/contoured seat, which distributes the worker’s weight so no
body parts gets all the pressure.
• Using an automated or conveyor system that transports the fabric directly to and
from the worker.
• Placing a pouch hanging from the table for keeping the frequently used tools by the
worker.
• Placing station on platform or using height-adjustable portable clothing racks or
tables.
▪ Use of adjustable-treadle so the worker can place it in a comfortable position and
get as close to the table as possible.
▪ Treadle should be placed closed to the leg of the worker so that the worker can
easily reach and operate it avoiding the strain in leg and bad postures.
• Edges of work surfaces should be padded or rounded, so the worker can rest their
arms against them with less strain.
• Tables should be slightly tilted(10°-25°)toward the worker, to enable them to see
the work more easily and to reduce awkward wrist postures.
• Enough leg space so that worker can move their leg easily.
• Height adjustable table should be used so that it can be altered varying on the
worker’s height and can be set at the elbow height of the worker.
• Chairs should be placed at an appropriate distance from the workstation, so the
workers can perform tasks without pulling their elbows away from the body.
• Providing vibration isolators(spring or pads) for seated work tasks.
• Tables should be equipped with supports for the forearms except where operators
work with hands close to the body, as is the case with some automatic machines.
• Required illumination level in sewing room is 500 Lux.
• Proper cross ventilation through adequate and properly placed windows and
presence of exhaust fans on the walls.
• Face mask can be used by the operators during sewing to avoid allergies’
 3.Evaluation of study workstation at home

side view Back view

The given picture shows the studying workstation at my home. Evaluating it from the point
of ergonomics it shows that there is a lot to be improved. The data taken from the above
picture are as follows:

▪ Height of the table from the ground: 72 cm

▪ Height of the chair seat from the ground: 42cm
▪ Length of the chair: 76 cm
▪ Leg space:14cm
▪ Width of the chair: 42 cm
▪ Lght intensity: 1278.6 lux
▪ Arm rest height: 61cm
▪ Back rest inclination: 30°

In the above picture the chair is not ergonomically proper it would make the person
tired and also lead to other bad postures. Also the light used for the above purpose is
not proper it is not concentrated at the point of working inspite it can be used for wider
range of view. Also if the height of table and chair should be taken in consideration then
it is only suitable for a particular person of particular height and physique and if there is
any person out of that range he/she would feel difficulty in performing the task. So to
make the above workstation ergonomically correct following improvements can be
done:

• Height-adjustable table should be used so that it can be used for any person of
varying height and physique.
• The chair used should have following properties:
Height-adjustable swivel chairs with following specifications
• Padded back rest with rounded edges that supports person’s lower back.
• A gently sloped or "waterfall” front edge from pressing into the back of the legs.
• A cushioned/contoured seat, which distributes the person’s weight so no body parts
gets all the pressure.
• Lumbar support: The curve in the back of the chair should support the lower spine,
following the natural curve of our spine.
• The laptop screen should be placed betwwn 20”-40” in front.
• Keep only things you use daily within reach and store everything else off tge table.
• The table desk should be just below elbow height.
• Extra footrest can be added under the table to support the body posture.
• “Goose neck “ light should be used for task lightning in this case studying so that the
intensity is concentrated in the working area rather than spreading in the not
required area.
• Also we can keep a thin ply in the metal cross are under the table where we can
keep not so frequently used material and this would increase the working area .
ss
Different postures while using the
workstation:

Use of foot rest during studying.

 REFRENCES

• Ergonomics handbook for the clothing industry.pdf

• Ergonomics checkpoints.pdf
• Introduction to human factors and Ergonomics for
engineers.pdf
• Ergonomics in cutting room.pdf
https://www.google.com/search?q=Ergonomics+in+cutting+room.pdf&oq=Ergonomics+in+c
utting+room.pdf&aqs=chrome..69i57j69i60.1595j0j8&sourceid=chrome&ie=UTF-8

• Easy ergonomics.pdf
• Ergonomics RE.pptx
Thank you