NATIONAL INSTITUTE OF FASHION

TECHNOLOGY, GANDHINAGAR

ERGONOMICS
Cutting Room
Ergonomics
Date : 10th oct. 2011

Under Guidance Of - Presented By -

Mr. Manoj Tiwari Abhinay Kumar
Satyam Singh
Shrey Vij
Rishab Tandon
Kuldeep Meena
 CUTTING ROOM IN TERMS OF
ERGONOMICS
• Unlike sewing room, the cutting room mostly consists of
equipments and workstations on which work is to be done only in
standing position.
• So, there must be equipments and workstations designed
according to the anthropometric data of human body in standing
postures.
• The postures are different from the sitting workstations here.
• Basically in the standing position the points which are taken under
consideration are worker’s height, arm length, hand length, Hand
breadth etc.
• Consideration is taken care of :
– Workplace design

– Task design

– Equipment design
 AVERAGE MEASUREMENTS OF
HUMAN BODY

http://www.disabled-world.com/artman/publish/height-chart.shtml
 ADVANTAGES OF STANDING
WORKSTATION

• Reach is greater in standing than in sitting.

• Body weight can be used to exert forces.
• Standing workers require less leg room than seated
workers.
• Lumbar disc pressures are lower.
• It can be maintained with little muscular activity and
requires no attention.
• Trunk muscle power is twice as large in standing than in
semi-standing or sitting.
STANDARD WORKING POSTURE
STANDING POSITIONS

NORMAL POSITION IDEAL POSITION

 IDEAL BODY POSTURE
• Maintain the “S” curve in your spine
• Feet flat on the floor
• Knees and hips at a 90 degree angle
• Elbows at 90 degree angle – do not lean on elbows
• Shoulders relaxed and elbows close to body
• Head and neck in the upright position
• Hands and wrist in the neutral position
Avoid: Poor body mechanics, twisted torso, slouching,
kneeling, squatting, neck rotation/side bending, bent wrists,
and reaching overhead.
 A WORKER’S REACH
• Usual work area/reach : (80-100 + 25) cm
• Occasional work area/reach : (80-100 + 50) cm
 CUTTING DEPARTMENT
• The primary tasks in the cutting department are:
– Loading the spreading machine

– Spreading the fabric

– Cutting the fabric
– Stacking cut pieces

 
LOADING THE SPREADING MA
CHINE
SPREADING THE FABRIC
CUTTING THE FABRIC
STACKING THE CUT PIECES
EQUIPMENTS USED IN CUTTING ROOM
AND THEIR ERGONOMICS FEATURES
 SPREADING TABLE
• Table dimensions : length - 340”(approx.)
• Width – 72”

• Height – 34”

Adjustable Air blower beneath

Height the table
• Ergonomic features of cutting table :
– adjustable height
– air blower beneath table for easy movement of
layers
– smooth edges
– width according to normal human hand movements

Height according to
normal human height
Smooth edges
MANUAL SPREADING MACHINE

Rollers for Points for width size

movement adjustment
• Ergonomic features :
– width size adjustable

– adjustable height according to table and worker

– manual edge control
– rollers adjustment for easy movement between one
table to another table
 STRAIGHT KNIFE

27” height easy to

handle

Handle for better

grip

Swivel base plate for movement

Handle for movement
to other tables
• Ergonomic features :
– Weight : 34 lbs(15.4 kg) easily moveable by cutting
person
– Height : 27”
– For better grip and easy movement extended holder
is present
– For transportation purpose on the upper part gripper
is present
– For steady and vibration free working base plate is of
metal, 8” long and 5” broad
– a security handle that automatically drops the
presser foot leg and stops the machine when the
handle is released
– ergonomic handle that reduces wrist strain
– a swivel baseplate that turns easily even in the
hardest materials
 END CUTTER

Control panel in worker’s

reach Track for
movement
of end
cutter
Long Handle for longer
reach
• Ergonomic features :
– For easy movement there is a gripper to move the
end cutter length wise
– Small in size
– Attached to table so that the movement is not
dependable only on the cutting man i.e. weight of
end cutter is distributed between table and the
cutting man
– A long rod is attached to the end cutter to move it
with the table length without the movement of the
operator
– Easy to attach and detach with tables
– Fitted on the tracks from easy to and fro movement
across the table
– Control panels are in the reach of cutting man
 BAND KNIFE Emergency
light

ADJUSTABLE Curve inserted for better

TABLE HEIGHT reach to the blade
Air flotation table
Adjustable Table height
according human height
• Ergonomic features :
– Adjustable table height

– Air flotation for easy movement of layers during use

– Additional Safety Device to ensure the operators
safety
– The lighting device to reduce operators fatigue
– Auto Catch Device, to catch the knife when the blade
is broken.
– A curvy portion is provided to fit the cutting man for
easy reach to the blade
BAND KNIFE WORKER’S REACH

80-100cm
25cm
50cm
 LABELLING GUN

Handle for grip

Extra plastic griper

• Ergonomic features :
– gripper is provided for fast use of the labelling gun

– small in size
– weight is less
– extra plastic grip is also provided
 FUSING MACHINE

Control panel near

the operator

Automatic sensor
• Ergonomic features :
– continuous fusing is done so no need to move the
cut pieces every time
– automatic sensor in case of any emergency
– 35” height of the machine bed which is according to
normal human height
– Control panel is near the operator’s position to avoid
any emergency
– Operator friendly side swing design
– Operator is protected from heat radiation
 GENERAL ERGONOMIC CONCERNS
DURING WORK
• Static postures
• constantly work with their arms above shoulder level

• Awkward body postures

• the height of the workstation
• Repetition of movements
• Standing in one position for long periods of time
• No foot rest
• Awkward wrist postures
• Workers should try not to twist their upper body when
placing objects besides them
• Vibration caused by different equipments
 PROBLEM SOLVING TECHNIQUES
• Avoid static postures

• For standing work, the height of the workstation should allow

workers to function with elbows at 90 degrees

• workers should try and sit for short periods of time while
working to give their leg and back muscles a rest

• Change position after a period of time

• There must be a raised foot rest provided for standing

workstations

• majority of work should be done between knuckle height and

shoulder level

• Workers should move their feet, instead of twisting at the waist,

in order to face the area where the object is going to be placed

• Avoid repetition of movements

• Assign job according to worker, not worker according to job

NORMAL WORK FLOOR ARRANGEMENT

• Anti-fatigue mats for those who must stand for extended

periods of time
• Footrest – to allow the employee to put one foot up and
change positions often
• Floor surface is free of obstacles and flat
• Keep work at comfortable height to maintain erect
posture
• Footwear with good support
 Avoiding MSDs needs Work Smarter,
Not Harder
• Work in neutral postures
• Reduce excessive force & repetition

• Keep everything in easy reach and at proper heights

• Minimize static unsupported postures and pressure
points
• Use proper lifting
• techniques and lift aides
• Ask for assistance with difficult tasks
• Take micro-breaks (stand, stretch, change tasks)
• Maintain a comfortable environment
GAPS IDENTIFIED IN WORK
ENVIRONMENT AND
EQUIPMENTS
AREAS GAPS IDENTIFIED SUPPORTIVE FINDINGS
Cutting table Work height too high Complaints of postural
discomfort and pain in
shoulders, neck and hands
Sorting table Work height too high Complaints of postural
discomfort and pain in
shoulders, neck and hands
Inadequate lighting Low level of lighting Complaints of visual strain and
blurred vision
Excessive noise Noise level exceeds 90dB Worker’s complaints
Dust Increased level in cutting Complaints of respiratory
section problems
Hot and humid work place Heat Humidity 23 to 57% Heat Workers complaints Identified
exposure as risk factor by hazard
identification and risk
assessment
Blade guard of the cutting Defects in design of blade Fifty per cent of workers
machine guard, non use of blade guards reported accidental cuts

General safety measure Absence of general safety Observed gaps

measures
Personal protective equipment Absence of personal protective Observation and reported
devices incidences
 SUGGESTED ERGONOMIC
FEATURES IN CUTTING ROOM
• Efficient spacing between the cutting tables, racks, band
knife machine, fusing machines for better movement of
man and material.
• Cutting table heights are according to normal human
height
• Dustbins are provided according to the height of the
cutting table and band knife machine
• Racks heights are according to the normal human’s hand
reach
• Fabric store is near the cutting room so less movement
of man and material
• The illumination level is kept to standard illumination
level i.e. 750 lx.
 Cont…
• Provision of local exhaust ventilation that uses suction,
based on the principle of a vacuum cleaner, is to be
encouraged in the cutting and stitching sections to
remove dust from the air.
• Workers are suggested to wear fine – mesh cloth dust
protectors.
• The handles should be made of flexible polyethylene
materials, which even after prolonged and regular use
give a comfortable feel.
• The blade guards of the cutting machines 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.
AN ERGONOMIC LAYOUT OF C
UTTING ROOM
 CONCLUSION
• During this project we came to know that ergonomics features
in the cutting rooms in most of the industries are very poor.
• Our observation turns out that modern equipments and tools
are manufactured based on ergonomic designs and suggestions.
• But the cutting room work floor management and the building
layout do not support the concern of workers and ergonomics.
• These interventions made in the units would help to improve
the work environment of the garment manufacturing units.
• This study demonstrates that there is ample room for
ergonomic improvements in the clothing industry.
• We need to continue to identify problems and, more
importantly, implement solutions to reduce the risk of injuries in
situations where we know problems exist.
• So, there is a huge scope of improvement in the field of
ergonomics in apparel industry.
REFERENCES
• PDFS
– Ergonomics In The Garment Manufacturing Industry

– Ergonomics Awareness Training

– Ergonomic Interventions To Improve Work Environment
In Garment
Thank you…