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A method of workplace design for sewing operations

Article · January 2011

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Bosiljka Saravanja
University of Zagreb
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 Paper Key Data (written by corresponding author)

1_ File name (dpn_a_no_familyname): 21260_a_2_Dragcevic

2_ Corresponding Author (dpn_familyname_name): 21260_Dragcevic_Zvonko
3_Email address: zvonko.dragcevic@ttf.hr
4_Title of Paper (textual name of paper): A METHOD OF WORKPLACE DESIGN FOR SEWING
OPERATIONS
21260_DRAGCEVIC_Zvonko / 26955_KIRIN_Snjezana / 23761_SARAVANJA_Bosiljka
6_Key words (key_word_1 / key_word_2 / …):: workplace design / sewing operations / ergonomic of sitting
/ workload

Abstract: The process of garment sewing belongs to piece
manufacturing processes and is performed on production lines
with a closed type of installed workplaces. The operations
involved are performed in a sitting posture and working cycles
of performing them are short (20-60s), with highly repetitive
moves, which often results in occupational diseases due to
extremely high psycho-physical loads. This is why it is
necessary to design the working system (man-machine-
environment) for each workplace in accordance with static and
dynamic anthropometric characteristics of each individual
worker. The paper gives an overview of the basic procedure in
workplace designing in sewing operations.
Key words: workplace design, sewing operations, ergonomic of
sitting, workload
1. INTRODUCTION
By the criterion of working process organisation,
manufacturing systems in sewing belong to the closed type of
workplace, with routine performance, where the operator
performs the operations of approximately similar
characteristics. To organise this type of work successfully, it is
necessary to design the workplaces in a proper manner,
selecting optimal methods of work for each technological
operation, which offers the benefit of reducing the psycho-
physical load on the worker, the incidence of injuries and
professional diseases, while, from the production point of view,
it results in increased productivity and efficiency of work.
The process of sewing is an integral part of garment
manufacturing. The work is performed in a sitting posture and
the operator uses his trunk and arms in sewing to handle the
workplaces and his feet to regulate sewing machine stitching
speed. This kind of work asks for a repetitive and coordinated
usage of the body, arms and legs, as well as a high ability to
concentrate sight. A conditionally forced body and head
postures often occur, physiologically improper sitting, isometric
loads to the legs and considerable load to hands and fingers.
Working body posture plays an important role in the operations
of sewing (Dillard & Schwager, 1997).
Improperly positioned working surface at the workplace,
not matched to his/her bodily height, results in permanent static
loads to the spine, arms and associated muscles. Such a
workplace often leads to Cumulative Trauma Disorders (CTD),
as well as pains and injuries in the discs, lumbar and cervical
parts of the spine (scoliosis and kyphosis). (Vezina et al, 1992).
2. WORKPLACE DESIGN
When designing workplaces in sewing processes, it is
necessary to create a dimensional balance of the man-machine-
environment manufacturing system, together with a
physiologically appropriate sitting posture, such that would
ensure quick and precise motor movements in positioning the
workplace and machine actuation, high level of movement
coordination, proper posture of the groin, back and cervical
parts of the spinal column, as well as a proper position of the
head.
Bodily measures and their mutual relationship differ from
one person to the other making it difficult sometimes to adapt
the working area to each individual operator. This is why the
data on static and dynamic anthropometry are used to determine
spatial conditions at particular workplaces. Proper matching
with anthropometric relations ensures dimensional match
between man and machine, which is reflected in beneficial
angles of the kinematic chains: foot-lower leg; torso-head;
torso-upper arm; upper arm-forearm-hand.
Proper arrangement of working zones ensures dynamic and
rhythmic work enables combined and simultaneous movements
to be performed by hands, legs and body, which all
considerably reduces workload on the operator of technological
sewing machine operation in garment industry. (Kirin et al,
2004).
3. THE PROCEDURE OF WORKPLACE
DESIGNING
The following parameters should be determined in
designing a workplace: sitting height, working surface height
and distance, zones of normal and maximum reach and
necessary fields of vision.
A group of static anthropometric measures of the operator,
related to the particular working process performed in the
sitting posture, should be defined when designing a particular
workplace: torso thickness (A), upper leg thickness (B),
popliteal lower leg thickness (C), upper leg length (D), shoulder
height when sitting (E), arm length (F), elbow height from the
sitting surface (G), forearm length (H), eye height when sitting
(I).
Workplaces in sewing processes are designed through the
following phases, (Fig.1):
 Working chair height – defined by the popliteal lower leg
length (C), with the addition of the ease for footwear (2 cm)
and pedal regulator thickness (5 cm). This defines the plane of
sitting as well (POS).
 Back contour plane (POL) is determined from torso
thickness (A) with the addition of 15 to 20 cm, representing the
distance of the torso from the working surface edge (OUP
plane).
 Working surface height (VUP) is determined according
to the thickness of the upper leg increased by 10 to 15 cm. The
space bounded by the planes POL, OUP and VUP represents
the borders of free space in which the operator has the
necessary degree of free movement.
 The zones of normal and maximum reach define the
abilities of arm movements in the working surface plane
(VUP). The zone of normal reach is defined by the movement
from the elbow (H), where cyclic movement are performed,
while the zone of maximum reach, or the zone of outstretched
arm (F), includes periodic movements.
 Angle of sight construction is determined according to
the central plane of sight (SLV), which is defined by eye height
when sitting (I). This enables the transfer of the standard line of
sight within the limits of comfortable eye rotation by 25 0 and
comfortable head flexure by 300 in the sagittal plane.
POL OUP
PG
Fig. 1. The procedure of workplace design according to the data
on operator’s static anthropometric measures
The procedure of workplace design described here offers
beneficial angles of the kinematic systems (foot/pedal
regulator: 90-1000; lower leg – upper leg: 90-110°; upper leg -
torso: 60-90°). Proper angles of kinematic systems also ensure
that the eyes are 30 to 40 cm from the central working zone of
sewing, resulting in high visual acuity, necessary to control the
sewing operation in a precise manner (Fig. 2). (Dragcevic et al,
2008).
POL OUP
PG
Fig. 2. Workplace designed for a normal sitting posture
The above posture is beneficial from the points of view of
both physiological and anatomic requirements (Fig. 2)
Workplaces were designed using this method during some
technical – technological projects funded by the Croatian
garment industry (Varteks; Kotka; Pounje; and others). The
model of workplaces designed and applied for actual sewing
operations was verified through video recording analysis and
using the OWAS (Ovako Working posture Analysis System)
and PAQ (Position Analysis Questionnaire) methods.
The method developed is based on statistical
anthropometric measurements of the operators. Having in mind
specific characteristics of the work in sewing processes (short
time of performing the operations), future investigations will be
based upon necessary dynamic anthropometry and operator's
body constitution: endomorphic, mesomorphic and ectomorphic
type. (Rogale & First Rogale, 2010).
The results indicated that the working postures and border
angles of the kinematic systems (spine, upper and lower
extremities, head) were within a normal and comfortable range,
ensuring only minimal static and dynamic loadings (Fig. 3).
a) b)
Fig. 3. Border working postures in sewing operation, with
associated angles of kinematic systems: workplace positioning
(a), machine-hand sewing of a workplace (b)
4. CONCLUSION
The basic method of workplace design presented here
offers considerably reduces psycho-physical loading of the
operator, while enabling, from the manufacturing point of view,
higher productivity or efficiency of the work performed. The
investigations described indicated that the most operators
working in sewing operations should be between 160 and 175
cm tall. With the operators outside of this range, it was
impossible to achieve, when designing the workplace, working
postures and angles of the kinematic system in the comfortable
area. Basic notions of this method were used to develop a
software package which enables a 3D visualisation of the
workplace designed. The method could also be applied to
workplace design in other manufacturing systems when the
work is performed in a sitting posture (various assembling jobs,
computer systems, office administration, etc.).
5. ACKNOWLEDGEMENTS
The paper presented is an integral part of the research
within the confines of the scientific project entitled "Intelligent
clothing and environment"; project code 117-1171879-1894,
financed by the Ministry of Science, Education and Sports of
the Republic of Croatia.
6. REFERENCES
Dillard, B. G.; Schwager, T.F. (1997). Ergonomic Equipment
Investments Benefits to Apparel Manufacturers,
International Journal of Clothing Science and Technology,
Vol. 9, No. 4, 285-300, ISSN 0955-6222
Dragcevic, Z.; Kirin, S. & Polajnar, A. (2008). Investigation of
Workplace Design for the Process of Sewing, Proceedings
of the 4th ITC&DC, October 5th to 8th, Dubrovnik, Croatia,
ISBN 978-953-7105-26-6, Dragcevic, Z, (Ed.), pp. 569-575
Kirin, S.; Dragcevic, Z. & Polajnar, A. (2004). Workload and
Fatigue in the Technological Sewing Process, Tekstil, Vol.
53, No. 5, 226-243, ISSN 0492 5882
Rogale, D., & First Rogale, S., (2010). Human Body
Constitution, In :Theoretical Aspects and Application of
Croatian Anthropometric System (CAS), Ujevic, D., (Ed.),
pp. 92-97, University of Zagreb, Faculty of Textile
Technology, ISBN 978-953-7105-28-0, Zagreb, Croatia
Vezina, N. et al. (1992). Components of the Physical Workload
of Sewing, Applied Ergonomics, Vol. 23, No. 4, 268-276,
ISSN 0003-6870
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