By,

Re-designing Finishing Ankit Singh

Nishant Singh
Workstations Shalu
Somyajyoti Majumder
The Following are the areas in the finishing department where we have tried to
redesign/ innovate workstations and /or processes.

T h e ISelect
ron Table T h e T r i m Record
ming
Operation

G a r m e nt M ult i Examine &

The methodology....
Design
H a ng e r C a r r ie r Analyze
Workstation Dimensions:
Area of iron table= 51.5 * 36.5
Height of iron table= 34
Area of Iron stand= 11.5 * 5.5
Area for operator to stand= 51.5 * 20
From The Above Picture Bending of the
neck and pressing of the toe against the
table is evident.

From the picture in the right excessive

bending of the upper torso is Evident.
 Quantifying Postural Problems
RULA
Rapid upper Limb Assessment Tool
is used to assess the stress on the
upper limb. This technique was
developed by Dr. Sue Hignett and
Dr. Lynn McAtamney , ergonomists
from University of Nottingham in
England .
http://ergo.human.cornell.edu/ahrula.html & ahreba.html
REBA
Rapid Entire Body Assessment is the
ergonomic technique to assess the
stress on different parts of the body
due to an operation. This technique
was developed by Dr. Sue Hignett and
Dr. Lynn McAtamney , ergonomists
from University of Nottingham in
England .
 1
2

4
0
1
3
2
2

A: Arm and Wrist Analysis

 3

6
1
5
3

0
2

B: Neck, Trunk & Leg

analysis.

Final Score: 6
 5

5
2

0
2

A: Neck, Trunk & Leg

analysis.
 2

0
2
1

2
2

B: Arm & Wrist Analysis.

 Calculating the Final
REBA Score:
Score A: 5
Score B: 2
Activity Score: 1 ( For short and
Repetitive motions)

4 1

5
 Understanding the Scores:

RULA Score:

6
1 OR 2= Acceptable
3 or 4= Investigate Further
5 or 6 = Investigate further and change soon
7+= Investigate and change immediately

REBA Score:
1 = Negligible Risk, No Action Required

5
2-3= Low Risk, Change may be needed
4-7 = Medium Risk, Investigate further and change
soon
8-10 = Investigate and implement change
11+= Very high risk and implement change
 Interactions
HM :
Lifting the 1.5kg iron.
Pushing the bar at the base to create Suction.
Long Standing hours may cause

MH
Excess steam may cause water blisters.

ME
Machine Changes the Environment by
producing heat and steam.

Effects:

Discomfort.
Shooting pain in toe.
Deep vein Thrombophlebitis.
Suction
presser Redesigned Hanging
workplace Press

the suction stand should be

improvised or redesigned such
that the operator doesnt have
to press it with the toe.
Instead, he has to press it with
the foot.

T h e i r o n i n g t a b l e w o r ks tati on m a y b e r e -
d e s i g n e d i n t h e f o l l o w i ng w a y s t o r e d u c e s o m e
o f t h e p r o b l e m at ic a r e a s .
 Morton's neuroma:
is thickening of the tissue
around the nerve between
the bases of the toes
caused by irritation,
pressure, or injury to one
of the nerves that lead
to the toes; this triggers a
response, resulting in
thickened nerve tissue
(neuroma)
 Hallux Valgus or a
bunion: is when the bone
or tissue at the joint at the
bottom of the big toe
moves out of place. Years
of abnormal motion and
pressure on the joint forces
the big toe to bend toward
the others, which causes
an often-painful lump on
the joint.
Problem:
At quality checkpoint
require workers to stand
for a very long period of
time that may injured
the spines.
Blood circulation is not
effective while standing
due to gravity.
 SOLUTION: Sit / Stand Stool

This would ease out the standing posture.

The angles of the stoppers can be changed and locked at suitable positions.
Also anti fatigue mats can be provided.
 Exhaust Fan

An Exhaust Fan can be placed at the

level where the pressing table ends.
This would suck away the extra hot
air/steam from the workstation.
It must be gaurded with a wire
mesh.

Spring Iron

The iron may be hanged from a

spring.
The recoil of the spring would
help in reducing the weight while
lifting the iron.
 The Trimming Operation.

The trimmer itself has a metal body that has

sufficient grip problems.

COMMON PROBLEMS-

it creates contact stress

more pressure at thumb and index
finger
 Carpal tunnel syndrome: Carpal tunnel
syndrome is numbness, tingling, weakness,
and other problems in your hand because of
pressure on the median nerve in your wrist and
may be caused due to repetitive movement of
wrist at awkaward positions, mainly ulnar
deviations.
 Suggestions

A newly designed plastic covered Thread trimmer.

It has gripper on both the ends thus distributing load evenly

on all the fingers.
It is plastic covered.
Also face masks should be used
Thank You