Assignment on TE 4225

Topics:

Ergonomics

Submitted To:
Alberuni Aziz
Lecturer
Department of Textile Engineering
Khulna University of Engineering & Technology

Submitted By:
Naimul Hasan
1621060
Department of Textile Engineering
Khulna University of Engineering & Technology

Date of submission: 31-March-2021

Ergonomics
 Department of Textile Engineering, KUET

1.0 Definition of Ergonomics

Definition of ergonomics

1: an applied science concerned with designing and arranging things people use so that the
people and things interact most efficiently and safely
— called also biotechnology, human engineering, human factors

2: the design characteristics of an object resulting especially from the application of the
science of ergonomics

Ergonomics is the science which deals with the relationship between man and his working
environments. It takes care of factors governing the physical and mental strains. Ergonomics
consists of words ‘Ergo’ (which means work), and ‘Nomos’ (which means ‘Natural Laws’). This
can also be termed as ‘Human Engineering’.

Ergonomics (or Human Engineering) is defined by I.L.O. (International Labour Organisation)

as “the application of human biological sciences in conjunction with engineering sciences to
the worker and his working environment so as to obtain maximum satisfaction for the
worker which, at the same time, enhances productivity”.

Thus ergonomics is a multi-disciplinary science comprising subjects like anatomy, psychology,

physiology, sociology, engineering, anthropology, physics, and medicine.

The task of ergonomics is to develop such conditions for workers, which are necessary to reduce
physical workload, to improve working postures, facilitate instrument handling, and thus
improves the quality of working life, reduce fatigue, maximise efficiency of production operators
and to minimise human errors.

Ergonomics helps to study the effect of working environment on health and safety and in turn on
productivity. The workers’ interest in the job to a greater extent depends on how comfortable and
safe is the workplace.

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2.0 Objectives of Ergonomics

Ergonomics means literally the study or measurement of work. In this context, the term work
signifies purposeful human function; it extends beyond the more restricted concept of work as
labor for monetary gain to incorporate all activities whereby a rational human operator
systematically pursues an objective. Thus it includes sports and other leisure activities, domestic
work such as child care and home maintenance, education and training, health and social service,
and either controlling engineered systems or adapting to them, for example, as a passenger in a
vehicle.

The human operator, the focus of study, may be a skilled professional operating a complex
machine in an artificial environment, a customer who has casually purchased a new piece of
equipment for personal use, a child sitting in a classroom or a disabled person in a wheelchair.
The human being is highly adaptable but not infinitely so. There are ranges of optimum
conditions for any activity. One of the tasks of ergonomics is to define what these ranges are and
to explore the undesirable effects which occur if the limits are transgressed—for example if a
person is expected to work in conditions of excessive heat, noise or vibration, or if the physical
or mental workload is too high or too low.

Ergonomics has two broader objectives-

1. To enhance the efficiency and effectiveness with which the activities (work) is carried
out so as to increase the convenience of use, reduced errors and increase in productivity.
2. To enhance certain desirable human values including safety, reduced stress and fatigue
and improved quality of life.

Thus in general the scope and objectives of Ergonomics is “designing for human use and
optimizing working and living conditions.”

Thus Ergonomics discovers and applies information about human behavior, abilities and
limitations and other characteristics to the design of tools, machines, systems, tasks, jobs and
environment for productive, safe, comfortable and effective human use.

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3.0 Discipline of Ergonomics

The development of a science-based application which is intermediate between the well-
established technologies of engineering and medicine inevitably overlaps into many related
disciplines. In terms of its scientific basis, much of ergonomic knowledge derives from the
human sciences: anatomy, physiology and psychology. The physical sciences also make a
contribution, for example, to solving problems of lighting, heating, noise and vibration.

Disciplines of Ergonomics

 Anthropometry
 Biomechanics
 Mechanical engineering
 Industrial engineering
 Industrial design
 Information design
 Kinesiology
 Physiology
 Psychology

Most of the European pioneers in ergonomics were workers among the human sciences and it
is for this reason that ergonomics is well-balanced between physiology and psychology. A
physiological orientation is required as a background to problems such as energy expenditure,
posture and application of forces, including lifting. A psychological orientation is required to
study problems such as information presentation and job satisfaction. There are of course many
problems which require a mixed human sciences approach such as stress, fatigue and shift work.

Most of the American pioneers in this field were involved in either experimental psychology or
engineering and it is for this reason that their typical occupational titles—human
engineering and human factors—reflect a difference in emphasis (but not in core interests) from
European ergonomics. This also explains why occupational hygiene, from its close relationship
to medicine, particularly occupational medicine, is regarded in the United States as quite

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different from human factors or ergonomics. The difference in other parts of the world is less
marked. Ergonomics concentrates on the human operator in action, occupational hygiene
concentrates on the hazards to the human operator present in the ambient environment. Thus the
central interest of the occupational hygienist is toxic hazards, which are outside the scope of the
ergonomist. The occupational hygienist is concerned about effects on health, either long-term or
short-term; the ergonomist is, of course, concerned about health but he or she is also concerned
about other consequences, such as productivity, work design and workspace design. Safety and
health are the generic issues which run through ergonomics, occupational hygiene, occupational
health and occupational medicine. It is, therefore, not surprising to find that in a large institution
of a research, design or production kind, these subjects are often grouped together. This makes
possible an approach based on a team of experts in these separate subjects, each making a
specialist contribution to the general problem of health, not only of the workers in the institution
but also of those affected by its activities and products. By contrast, in institutions concerned
with design or provision of services, the ergonomist might be closer to the engineers and other
technologists.

It will be clear from this discussion that because ergonomics is interdisciplinary and still quite
new there is an important problem of how it should best be fitted into an existing organization. It
overlaps onto so many other fields because it is concerned with people and people are the basic
and all-pervading resource of every organization. There are many ways in which it can be fitted
in, depending on the history and objectives of the particular organization. The main criteria are
that ergonomics objectives are understood and appreciated and that mechanisms for
implementation of recommendations are built into the organization.

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4.0 Ergonomics Risk factor

Ergonomic risk factors are conditions of a job, process or operation that contribute to the risk of
developing work-related musculoskeletal disorders (MSDs). This includes damaged muscles,
nerves, tendons, ligaments, joins, cartilage or spinal disks. The main ergonomic risk factors that
can cause MSDs are awkward postures, forceful exertions and repetitive motions.

According to the Bureau of Labor Statistics, MSDs account for 30% of lost workdays and one
out of every three dollars spent on workers' compensation in the United States annually. To
reduce the frequency and severity of MSDs in the workplace, it is important to eliminate
ergonomic risk factors that are known to contribute to their development. 

Awkward Postures 

Posture determines which joints and muscles are used in an activity. It also affects the amount of
force required to perform a job. For example, more stress is placed on spinal discs when lifting,
lowering or handling objects when the back is bent or twisted than when the back is straight. 

Tasks requiring repeated or sustained twisting of the wrists, knees, hips or shoulders create
increased wear and tear on joints and muscles in those areas. And activities requiring frequent or
prolonged work over shoulder height can be particularly stressful on the body. 

Forceful Exertions 

Work that involves forceful exertions—such as lifting, pulling, pushing, gripping or pinching—
place higher loads on muscles, tendons, ligaments, joints, cartilage, and spinal discs. Prolonged
or frequent activities with high amounts of force can cause fatigue. If there is inadequate time for
rest and recovery, these activities can lead to musculoskeletal problems. Force requirements may
increase with: 

 Increased weight and bulkiness of the load being handled or lifted

 Increased speed or acceleration of movement (e.g., jerkiness)
 Presence of localized or whole-body vibration

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 Use of the index finger and thumb to forcefully grip an object (i.e., a pinch grip compared
to a power grip)
 Use of small or narrow tools that limit grip capacity. 

Repetitive Motions

If motions are repeated frequently and for long periods of time, like an eight-hour shift, a buildup
of fatigue and muscle tendon strain can occur. Tendons and muscles often recover from the
effects of stretching or forceful exertions if there is sufficient time between exertions. Repetitive
motion is especially dangerous when combined with other risk factors, such as awkward postures
or forceful exertions. 

Duration 

Tasks that require the use of the same muscle groups for long periods of time increase the
likelihood of fatigue. In general, the longer the period of continuous work, the longer the
recovery time required.

Contact Stress 

Repeated or continuous contact with hard or sharp objects—such as nonrounded desk edges or
unpadded, narrow tool handles—can create pressure over one area of the body (e.g., the forearm
or sides of the fingers) and reduce nerve function and blood flow. 

Vibration 

There are two types of vibration: local and whole body. Local vibration occurs when part of the
body comes into contact with a vibrating object, such as a power hand tool. Exposure to whole-
body vibration can occur while sitting or standing in vibrating environments or objects, such as
heavy-duty vehicles or large machinery. 

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Other Conditions 

Workplace conditions that can influence the presence and magnitude of these risk factors
include: 

 Temperature extremes
 Not enough recovery time
 Machine or assembly line paced work 

The best way to control ergonomic risk factors is to first watch employees performing their jobs.
Be sure to document any risk factors using an ergonomic risk factor checklist and develop
methods to eliminate them. Checklists of ergonomic risk factors are a good way to ensure that all
risks have been considered during the observation. 

If risk factors are present, determine their severity, duration and frequency. For example, if an
employee lifts a heavy object (forceful exertion), determine how much the object weighs, how
long it takes to perform the lift and how often the lift is required. The more information you have
about the task, the easier it will be to develop solutions.

The three common methods used to control ergonomic risk factors are: 

 Engineering controls—Changes to the process, workstation layout, tool designs or

material handling techniques to reduce or eliminate hazardous conditions
 Administrative controls—Changes work practices and management policies, such as
longer breaks, job rotation, adjusting work pace and employee training
 Personal protective equipment (PPE)—Equipment such as wrist braces and
antivibration gloves; PPE is the least effective method of and should be used as a last
resort

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5.0 Benefits of Ergonomics

Ergonomics is designing a job to fit the worker so the work is safer and more efficient.
Implementing ergonomic solutions can make employees more comfortable and increase
productivity. Ergonomics is important because when you’re doing a job and your body is
stressed by an awkward posture, extreme temperature, or repeated movement your
musculoskeletal system is affected. Your body may begin to have symptoms such as fatigue,
discomfort, and pain, which can be the first signs of a musculoskeletal disorder. Here are nine
impressive benefits of ergonomics in the workplace.

1. Improves Health

People who work in ergonomic workplaces have improved health. It typically starts within the
cardiovascular system and spreads to other areas. Your heart will be healthier than it would be if
you were working in a standard environment.

Also, you and your employees will feel less tension in your body because you’ll be adjusting the
workstations to fit your height. These natural positions will prevent you from straining your eyes
and necks. You’ll also reduce swelling in your legs because your blood flow will be optimal.

2. Improved Mental Insight

When you feel comfortable, you can focus better on the task at hand. Ergonomics decreases pain,
strengthens muscles, and increases blood flow. Combined, this improves mental insight.

You and your employees will experience less anxiety, increased awareness, improved moods,
and focus. This means everyone can concentrate on their work more. The better focused they are
the higher productivity levels.

3. Higher Productivity Levels

The better focused your employees are, the high level of productivity they can have. Ergonomics
combine different ideas to make workstations feel more natural. These lead to increased
productivity because they’ll be more comfortable and focused.

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Your business needs productivity levels to increase to be successful. You can change your
workplace to be better for employees. The better they feel about their work, the more they’ll
want to produce.

4. Decreased Pains

Ergonomics is meant to make things feel more natural and safe. Due to this change, your body
will be less strained and your health will improve. These combined will lead to decreased pain.

When employees feel uncomfortable, it affects their ability to work. You can work at a standing
desk, or trade the phone for a headset to start. The less pain your employees have, the better they
can focus on the quality.

5. Higher Quality Work

The benefits of ergonomic workspaces range from the body to the quality of work. Aches, pains,
fatigue, and other problems can take a toll on a worker. Ergonomics can eliminate those issues
and help workers work.

When people feel comfortable, they can focus on high-quality production. This combined with
increased productivity levels will keep your consumers happy too.

6. Eliminates Hazards

Part of creating a more productive work environment is eliminating the daily hazards that can
hurt your employees. These distractions are unsafe and can lead to worse consequences later. Pay
attention and know your office so you can assess what hazards exist.

Another good idea is to ask your employees what hazards they face daily. By asking for their
input, you’re showing that you care. Implementing the change will show them they’ve been
heard.  

7. Increased Employee Engagement

Your employees will notice that your business provides the best conditions for increased
employees’ health and safety. Because they won’t be experiencing fatigue and discomfort, you’ll
see an increase in the employees’ involvement. You’ll find their motivation will increase the
more they feel taken care of by the company.

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This can reduce the turnover rate and make your business one others want to work with. Your
employees’ opinions matter, and you can benefit from it by utilizing ergonomics.

8. Encourages Safety

Ergonomics will create a safer work environment and increase awareness. You’ll remove
hazards, improve workstations for less discomfort, and teach your employees to update their
spaces with safety in mind.

Not to mention, the health benefits that come with ergonomics keeps employees healthy at work.
This will encourage safety on another level. You can keep your work consistent and stable by
providing employees with a safe environment they can thrive in.

9. Happier Employees, Happier You

The better you utilize ergonomics, the happier your employees will be. They’ll enjoy coming
into work more than they did before, and it will affect those around them. You will notice a
difference in your own happiness.

When your employees are happy at work, their productivity levels will increase. The better they
do, the better your business will do. These are all factors in keeping everyone safe and happy.

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6.0 Elements of Ergonomics

Training is a critical element of a successful occupational ergonomics program. Learning

opportunities provide people with the means necessary to complete the steps of the ergonomics
improvement process. These key steps include identifying risk, reducing risk, verifying risk
reduction, managing injuries and maintaining program sustainability.

Elements of Ergonomics

Step 1: Identify Risk Factors

Step 2: Involve and Train Management and Workers

Step 3: Collect Health and Medical Evidence

Step 4: Implement your Ergonomic Program

Step 5: Evaluate Your Ergonomic Program

Step 6: Promote Worker Recovery through Health Care Management and Return-to-Work

Step 7: Maintain Management Commitment and Employee Involvement

Training is critical, especially since it can be one of the biggest investments a company makes in
its ergonomics agenda. Therefore, it must be well-planned, focused and coordinated. This article
describes critical elements for success with the training portion of your ergonomics process, and
explains the reason for training, whom to train and in what order and the content of each level of
training.

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Reason for Training

The sole purpose of training in ergonomics is to provide people with the skills, knowledge,
abilities and tools to accomplish their designated responsibilities. These people form the support
infrastructure for your ergonomics process. The responsibilities vary with each different role in
the process (see chart).

Before you begin training, plan what you want to accomplish. This includes defining the
ergonomic improvement process and process measures for your site or organization and
establishing the key roles and responsibilities of people supporting the process. Use this
information to determine the need for training, the learning objectives and training content.

Training Sequence

While all groups play an important role in the total process, the order of training people in key
roles has a major impact on the success and sustainability of the ergonomics process. Do not
begin by providing awareness training for employees. Although this is simple and fun to do, a
program based solely on awareness will not survive. Before you paint a wall, you must prepare it
to allow the paint to stick, provide good coverage and last over time. Before you train
employees, you must prepare the support infrastructure (key roles) with skills training. The
recommended sequence is as follows:

1. Start by educating senior managers to obtain their sponsorship, guide them into leadership
roles and establish direction and goals for the ergonomics process.

2. Train the person or persons responsible for managing the ergonomics process. The role of the
ergonomics process manager is to coordinate and deploy all elements of the process. To
accomplish this, he or she must understand the site's or organization's goals and expectations for
the ergonomics process, identify supporting roles and develop plans for implementation and
communication.

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3. Develop the skills, abilities and confidence of ergonomics team members, engineering and
maintenance personnel, and medical/workers' compensation resources. Effective skills training
will establish a small team of resident experts who can address tough ergonomic challenges
brought to them by managers and supervisors.

 Ergonomics team members typically have responsibility for assessing ergonomic risks
and leading improvement efforts. To facilitate these tasks, they must be provided with
easy-to-use tools and methods for risk assessment, risk prioritization, root cause analysis
and a process for implementing changes.
 Engineering and maintenance personnel have a critical role in designing and installing
workstations, work environments and tools that minimize exposure to ergonomic risk
factors. They require tools, methods and resources to design equipment within the
capabilities of the working population. As a result, they will be able to assist ergonomics
teams in improving the existing workplace (reactive), and ensure that all future
equipment and tools do not pose ergonomic risk (proactive).
 Workers' compensation managers and medical personnel must be prepared to deal with
and manage work-related musculoskeletal disorders (WMSDs) when they do occur.
Training in current practices will enable them to manage injuries and reduce the time and
cost of returning injured employees to work.

4. Provide managers and supervisors with awareness training and coaching to affect work
practices and behaviors and to improve workplace conditions. In their supervisory roles, these
individuals are best prepared to assist with the implementation of improvements identified by
ergonomics team members and engineering and maintenance personnel. In addition, they are the
most influential people to affect employee safe work practices.

5. Provide employees with awareness training to prepare and empower them to identify potential
ergonomic issues in their workplace and to adjust the workplace to control the issues or escalate
issues to their supervisors for assistance.

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Organizations that establish clearly defined roles and responsibilities, and provide training to
ensure the capability to meet these responsibilities, create a strong internal support infrastructure.
The infrastructure ensures that employees receive support when they take responsibility for
improving their workplace and practices.

Critical Success Factors

In summary, the critical success factors for effective, efficient and sustainable ergonomics
training are as follows:

 Base the need for, and content of, training on the performance expected from the
participants. Well-defined roles and responsibilities of the support infrastructure are your
blueprint for ergonomics training.
 Prepare the wall. The training sequence begins at the top of the support infrastructure and
ends with employee awareness training.
 Hold people accountable for performing the activities and achieving results using the
skills and methods provided in training.

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7.0 Ergonomics in sewing floor

Ergonomics aims to make sure that tasks, equipment, information and the environment suit each
worker. It is a field of study that has contributed to the understanding of work-related stresses
and solutions, anatomy and physiology, anthropometrics, biomechanics, psychology, and
industrial design and engineering. Industrial Engineering Terminology (revised edition, 1991),
defines ergonomics as: “The application of a body of knowledge (life sciences, physical science,
engineering, etc.) dealing with the interactions between man and the total working environment,
such as atmosphere, heat, light and sound, as well as all tools and equipment of the workplace.”
It is indeed a highly interdisciplinary field which helps the worker to attain higher productivity
due to less fatigue, safer working environment (fewer accidents), lesser absenteeism and reduced
labour turnover.

As of ergonomic intervention include the human-machine interface, environment, hardware and

work posture. Some of the factors that affect ergonomic interests are: Climate (Temperature,
Humidity and Airflow – Ventilation); Noise, Illumination, Vibration and Radiation; besides
Work Time/Shift, Work Overload, Ageing, Material Handling, Stress or Strain and Load.

ETON overhead material handling in UPS (Unit Production System)

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Human-machine interface

The human-machine interface involves Displays, Text Clarity and Controls. Display must be as
clear and as easy to read as possible. The display must meet the needs of the human beings
operating the machine or the equipment. Text clarity should be on KISS (Keep It Short and
Simple) principle; and the readability should be as per Gunning Fog Index. Control factors to be
accounted for are: Speed – For example, the reverse stitch switch in a programmable lockstitch
machine is located close to needle point for footer response. If fast response is required, then
operation will be done by hand or fingers; Force – It should be well-balanced; excessive force
should be avoided and an amount of certain force is necessary to prevent a control from being
accidentally tripped; Grouping – Depending on the frequency of use, buttons or switches with
similar functions should be grouped together; Accuracy – Which can be like in the form of using
a mouse to select icons on a screen; Illumination – Colour codes, shapes and textures should be
clearly legible, having clear visibility from wide angle and with the right intensity of
illumination; Population stereotypes – The routine activities should conform to the prevailing
convention, like sewing machine flywheel turning anti-clockwise; a valve turning clockwise
which means ‘close’; red which means ‘stop’ (danger); green which means ‘go’ (safe to go);
yellow line which means ‘machine working limit’, are some of the examples.

ETON overhead material handling in UPS (Unit Production System)

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Environment

Environment includes workplace layout, automation and manufacturing systems.

Workplace Layout

The tendency of operators to work in the hunched posture also suggests a potential conflict
between workstation geometry and operator dimension. Analyses indicate that most commonly
operators position the chair away from the work surface in order to allow a knee angle of 110
degrees or greater. Factors limiting operator access to the workstation are the location of the
treadle which is too close to the proximal edge and various other obstructions (motors,
pneumatic equipment and machine guards) beneath the table. While typical recommends knee
room averages of about 46 cm, the presence of these obstructions, in some cases, limits available
space to less than 26 cm. In consensus with the ergonomist’s recommendation, numerous
operators express a strong preference for positions in which the rear of the workstation is tilted
upwards.

Automatic Workstation –1911-41912-4 – Duerkopp Adler

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Automation

Automation, for example, can reduce the skill requirements of a complex positioning and
guiding task and also eliminate many high-risk hand and wrist postures and the frequency of
hand movements, thereby reducing the exposure to common repetitive trauma disorders.

Right combination of stool and table height is essential for correct posture. Operators typically
adopt hunched posture resulting in discomfort in the back and neck.

Manufacturing Systems

Notable success in attempts to introduce modular manufacturing are found in reducing repetitive
strain injuries. Anecdotal reports suggest that, after a period of adjustment, many workers
experience significantly decreased levels of musculoskeletal discomfort due to the increased
variety in movements and improved postures at the standing workstations and the motivational
factors. Increased morale and workgroup cohesiveness, along with substantially reduced
absenteeism, have also been seen in successful implementations.

Modular Manufacturing

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Hardware

Hardware includes tools and seating. The vast majority of operations are performed in a seated
position. Seating encountered in the sewing environment typically consists of straight-backed
wooden or metal chairs. In most places, the provided chairs lack any cushion for reducing
compression and fatigue, lack adjustable backrest, and often are of improper height. Most
operators (91%) customize their chairs with homemade cushions on the pan and backrest in order
to adjust the height and increase pliancy. Most cushion adjustments increased seat height by 3-6
cm when compressed. In a study, the workers reported almost 90% reduction in discomfort
frequency when using the ergonomically-designed chairs.

Right combination of stool and table height is essential for correct posture. The height of
adjustable sewing table stands ranges from 70-80 cm and stool height used in Indian garment
industry ranges from 45-48 cm. The indicative anthropometric data (based on a pilot study done
by GMT department in NCR) of sewing workers, suggests that only 50% of the workers are
comfortable with existing machine height and 32% of workers are happy with existing stool
height. Customizing table and stool height combination shows improvement of performance and
reduction of SAM value by 4-12%.

Biofits AFLEX chair – EA4B4C series

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Use of attachments, work-aids and tools

The production of a ‘felled seam’, the kind of double overlapped seam found on the side of
denim jeans, requires an awkward posture of wrists, hands and fingers to evenly guide the fabric
through the folder. An automated felled seamer (senses the fabric edge inside the folder)
simplifies the job even further, allowing the operator to use nearly neutral wrist and hand
postures throughout the operation. A puller feed reduces the force operator needed to exert in
many operations, like elastic attach, waistband attach, jeans inseam, etc. Use of binders and
hemmers reduces finger manipulation job of an operator in many operations like hemming, neck
binding, pintucking, etc. Even a pair of ergonomically-designed scissors will benefit workers.

Work posture: Improvement through training

Much of the reported discomfort in the back and neck can be attributed to the working posture of
the seated operators. In response to job and workstation characteristics, operators typically adopt
a hunched working posture. Several workers stated that this posture is necessary to obtain
maximum production and wages. Such postures have been cited as a factor in muscle fatigue and
discomfort. The tendency of operators to work in this hunched posture can be attributed to at
least three factors: the visual demands of the work, the geometry of the workstation and
inadequate seating, which can be corrected by using right equipment.

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(Wrong posture) and (Correct posture)

But substantial improvement in both posture and frequency of musculoskeletal discomfort can
also be achieved by proper training and awareness about right posture. For example, a mean
improvement of back angle by 9 degrees among workers decreases musculoskeletal pain by
90.3%. Moreover no change in production is noticed. Posture is constrained by both the visual
and manual aspects of the task and the design of the sewing machine and table have a
considerable influence on the posture adopted. The potential for improvement of industrial
sewing machines was investigated and a study of the effects of two design parameters was made
(table inclination and view of the needle).

The study indicated that both trunk posture and head/neck flexion could be improved
significantly by altering their design parameters. Trunk posture was found to be strongly related
to the manual aspects of the task, and could be improved by altering the working positions for
the arm. Head posture was most influenced by the view of the task/needle and could be improved
by enhancing the visual condition for the task.

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The right type of lighting is important in garment manufacturing – Save on electricity, save on
energy

Occupational hazards

A study has found that finishing workers in the clothing industry may be exposed to stain
removing chemicals, thus subject to hydrazine compound induced contact eczema. Industrial
sewing work involves a pattern of shoulder muscle activity which induces fatiguing processes in
the shoulder and neck regions. Furthermore, since the static shoulder muscle load was
independent of muscle strength, i.e. shoulder does not make any movement during sewing but
the muscles are loaded due to the movement at elbow-wrist-finger, factors other than working
posture may be of significance for the static muscle load. Further, the babies whose parents
worked in the clothing industry were significantly smaller for gestational age than were babies of
other manual workers.

According to international benchmark standard, nearly 60-95% of operations of common product

categories (like shirt, trouser, jogging suite, etc.) are repetitive in nature. A significant
relationship exists between hand pain and repetition rates. There are on an average 29 left-hand
and 25 right-hand posture changes per cycle. High degrees of manual manipulation are
associated with higher levels of physical discomfort almost throughout the body. Greatest
discomfort levels are concentrated in the neck, upper and middle back, right shoulder and hands.

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A survey among sewing workers in NCR during the year 2000 revealed that nearly 80% of them
had low back problem while 62% had shoulder pain.

Factors Affecting Ergonomic Interests

Climate
Physiological demands are placed on an operator through the performance of a given job or task,
the thermal environment (temperature and humidity) and the rate at which muscular fatigue
develops. Build-up of fatigue means increasing the risk of accidents and injuries and also can
distract operators from the task at hand. While basic metabolism rate is 1.0 Kcals/min, different
body positions and movements require different calories. While sitting requires 0.3 Kcal/min,
standing and walking require 0.6 and 3.0 Kcals/min, respectively. Type of work also decides
calorie requirement. Sewing requires 1.0 to 3.5 Kcals/min, CAD operator requires 0.2 to 1.2
Kcals/min, while loading workers at finished goods warehouse requires approximately 7.0
Kcals/min.

Ergonomically designed scissors

Illumination
Most sewing operations are visually demanding, requiring the precise stitching of thread into a
fabric with which there is little or no visual contrast. Hunched working posture is also in order to
see their work. Illuminating Engineering Society of North America (IESNA) recommends a
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value of 300 fc (foot candle) for visually intensive tasks with low contrast at the point of
operation (POO). A pilot study conducted in the year 2000 among garment sewing workers,
reveals that 45% of them faced pain in eyes. The best way to minimize the eye pain and reduce
posture related injuries is to use needle lights.

Ordinary designed scissors

The ageing worker will need an ergonomically-friendly environment in order to do a quality job.
Vibration and Radiation
Vibration causes visual damage like blurring of subjects, resulting in undue strain on eyes. It also
causes motion performance effects. If vibration frequency is above 20 Hz, it leads to nervous
system disorder, if it 20 Hz – then spinal problems are detected and at less than 20 Hz, digestive
complain happens. Machines with highest leakage of radio frequency electromagnetic fields
were found in the readymade clothing industry in plastic welding operation for carton strapping.

Work time/shift
To result in optimum performance, the human circadian rhythm (8 hour work, 8 hour free time, 8
hour sleep) should be considered as normal. A sufficient number and length of breaks should be
given. Recognized shift-work programmes should be utilized (day- and night-shift alternating).
Optimal temperature to work is 98.60 F ± 1.80 F (370 ± 10 C), which is the human core
temperature. Rising of the core temperature means the worker will suffer from a heat disorder

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(heat stroke, heat exhaustion). If the heat and humidity levels rise above the comfort zone,
energy is mainly diverted toward keeping the body cool.

Material handling
Unlike in conventional manufacturing operations, where unfinished garments are carried,
dragged, or wheeled on specially-designed carts between workstations, a computer-controlled
overhead conveyor (UPS) may be used to move partially assembled garments from one
workstation to the next. The UPS reduces horizontal reach requirements and eliminates heavy
lifting by the operators. It resulted, however, in increased vertical reach requirements and
increased wrist pronation during acquisition of materials. A survey among UPS users indicated
slightly higher frequencies of hand and leg discomfort than among their counterparts who
utilized conventional materials handling. Also some operators complained about a perceived
increase in the noise level (95-97dB) and reported temporary auditory threshold shifts during and
after the workday.

In contrast, PBU system has problems of heavy lifting by helpers or supervisors and upper body
movements (operators twisting their upper body to reach for garment bundles).

Nature of work
Static work is another situation where an unacceptable build-up of fatigue may occur. It is
performed by the muscles in any activity that involves holding a position for a certain period of
time. Some examples of static work are holding things with the hands (inspection), bending or
leaning forward (picking up bundles by sewing operators), standing without moving or sitting in
the position (thread trimming, spotting), working with the arms extended (inspection), etc.
whereas some of the examples of dynamic efforts are materials handling (lifting, pulling,
pushing and carrying).

Ageing
Due to ageing, the loss of motor reunions to skeletal muscle cells resulting in decreased nerve
simulation contribute to the cause of muscle atrophy, the decrease in the number of neurons and
decrease in muscle fibre area, reducing the size of individual motor units in the skeletal muscle.

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Thus, an increased number of motor units must be activated in order to exert force on a body of
mass. For this reason, exerting force on an object requires increased effort from the elderly and
also results in lack of fine coordination. Body weight increases till 50-59 and then starts
reducing. Body stature also changes with age; it decreases 30-39 onwards at a rate of 1.2
cm/decade.

As workers start aging, their biological and psychological capacities change thereby affecting
their performance abilities. Environmental design can compensate for declines in functional
capacities and take advantage of the experience and wisdom of older workers to permit ideal
productivity. “In general, they have fewer accidents, declining absences, and equal or higher
productivity than the younger workers. The elderlies possess better judgement, reduced risk,
caution and stability and of course company loyalty.

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