By:

Pratik Raj
Priti Raj
Sonal
Yukti Dua

INDUSTRIAL End Term Jury

ENGINEERING
 Basic Working

OVERLOCK Conditions
Ergonomics

MACHINE Motion Economy

WOODGROVE 2
BANK
 BASIC WORKING
CONDITIONS
• Ventilation
• Lighting
• Occupational Safety and Health Hazard
• Layout and Housekeeping
• Noise and Vibration
• Ergonomics

WOODGROVE 3
BANK
VENTILATION

• Since a lot of machines are

continuously working in the GC
lab and the number of students is
high too, it tends to get very
stuffy and suffocating.
• To combat this problem, we can
ensure; larger space, lesser
students and temperature.
• Presence of exhaust fans on the
walls can also be beneficial.

WOODGROVE 4
BANK
LIGHTING
Insert or Drag & Drop your photo
• We can use adjustable task
lighting to make it easier for the
student to see stitching
throughout the work.
• Ensure tube lights are replaced
from time to time, so they are
functional.
• Required illumination level in
sewing room is 500 Lux.

WOODGROVE 5
BANK
OCCUPATIONAL SAFETY AND HEALTH HAZARD

• A needle guard  can be used

which provides a barrier to
prevent fingers from wandering
into the path of the sewing
machine needle.
• At least 2 fire extinguishers
should be installed inside the GC
lab. 
• Face masks should be worn to
prevent cloth fibres from entering
the mouth and nose, which fly
away at the time of fabric
trimming.

WOODGROVE 6
BANK
LAYOUT AND HOUSEKEEPING

• Atleast 0.5 m x 0.5 m area should

be given to each student for
stitching on overlock machine.
• The aisle space should be 1.5 m
in width.
• A dustbin should be kept beneath
the trimmer of the overlock
machine.

WOODGROVE 7
BANK
NOISE AND VIBRATION

• Use a sewing machine vibration

pad to absorb all the noise and
vibrations the machine produces.
• The machine should be placed on
a flat surface.
• Reduce the sewing speed.
• The current overlock machines
should be replaced by quieter
models to reduce noise.

WOODGROVE 8
BANK
 ERGONOMICS
An applied science concerned with designing
and arranging things people use so that the
people and things interact most efficiently and
safely.

Workstation Components:
• Stool
• Table
• Treadle and Pedal
• Arm Support

WOODGROVE 9
BANK
STOOL
Problem
• Stools in the GC lab lack cushioning, back
rest and adjustability.
• Students have to sit for long periods in the
same position resulting in soreness of the
back, neck, buttocks and reduced blood
circulation to the legs
Solution
• Chairs provided should have:
1. Easily adjustable height and padded back rest
with rounded edges that supports student’s
lower back.
2. With wheels that lock.
3. Cushioned seat which distributes the student’s
weight so no body part gets all the pressure.
4. Swivel motion, so that students do not have to
twist to reach the side or behind.
WOODGROVE 10
BANK
LUMBAR LORDOSIS
The biggest problem faced by sewing operators.
Problem
• When standing erect, the lumber portion of
the spine is naturally curved inward
(concave), that is, it is lordotic.
• Nachemson and Elfstrom (1970), found that
unsupported seating in an upright, erect
posture(forced lordosis) resulted in a 40%
increase in pressure compared to standing.
Solution
• It is seen that a 2 inch thick lumber support
with a seat back rest angle of 90 degrees have
a marked impact on maintaining lumber
lordosis.
• Andersson (1987) reports that using of a
reclined backrest has a marked effect with
considerable reduction in pressure by
reclining backrest from vertical 90 to just 100
to 110 degrees.
WOODGROVE 11
BANK
TABLE
The surface on which we mount the sewing machine.
Problem
• Students tend to have awkward shoulder,
elbow and wrist postures while sewing
because of improper table height.
• Postures due to improper table height tires the
neck, shoulder and upper back muscles and
results in muscle pain.
Solution
• Provide height adjustable tables so the work
is at elbow height and wrists are kept straight.
• Edges of work surfaces should be padded or
rounded so that students can rest their arms
against them.
• Tilt table can also be used so that the students
with bi-focal lenses can see the work easily
and to reduce awkward wrist positions.
WOODGROVE 12
BANK
TREADLE
The pedal that we push with our feet to start stitching.
Problem
• Students operating a treadle for prolonged
periods tend to have awkward and
unbalanced posture.
• Students required to apply a constant treadle
force tend to maintain static lower extreme
postures.
• Students may also tend to have poor posture
if treadle is too close or too far away.
Solution
• It is recommended to install a footrest beside
the sewing pedal which should be:-
• The same height and at the same angle and
front/back position as the Pedal.
• Wide enough.
• Solidly fixed with a non-skid surface.
• Wider pedals can be used as they encourage
belle, posture and allow proper spacing
between feet.
WOODGROVE 13
BANK
ARM SUPPORT
Problem
• During sewing, the shoulders and the upper
arms are strained by downward force, which
results in shoulder pain, and forearm is prssed
onto the surface.
Solution
• The students should be able to comfortably
rest their forearms without pressure on a large
working area (with well-rounded table
edges).
• Newly developed, ergonomically designed
sewing tables have adjustable arm supports
where students can rest their forearm.
WOODGROVE 14
BANK
Motion economy is the
process of minimizing
the physical and
perceptual loads
imposed on people
engaged in any type of
work.

WOODGROVE 15
BANK
 PRINCIPLES OF MOTION
ECONOMY
• Principles that apply to the use of human body
• Principles that apply to the workplace
arrangement
• Principles that apply to the design of tooling and
equipment.

WOODGROVE 16
BANK
USE OF HUMAN BODY

• The two hands should begin as well as complete their motions at the
same time.
• The two hands should not be idle at the same time except during
periods of rest.
• Motions of the arms should be symmetrical and in opposite directions
and should be made simultaneously.
• Hand and body motions should be made at the lowest classification at
which it is possible to do the work satisfactorily.
• Momentum should be applied by the worker to help the him, but
should be reduced to a minimum whenever it has to be overcome by
muscular effort.

WOODGROVE 17
BANK
• Continuous curved movements are to be preferred to straight-
line motions involving sudden and sharp changes in direction.
• "Ballistic" (i.e. free-swinging) movements are faster, easier and
more accurate than restricted or controlled movements.
• Rhythm is essential to the smooth and automatic performance of
a repetitive operation. The work should be arranged to permit
easy and natural rhythm whenever possible.
• Work should be arranged so that eye movements are confined to
a comfortable area, without the need for frequent changes of
focus.

WOODGROVE 18
BANK
WORKPLACE ARRANGEMENT

• Definite and fixed stations should be provided for all tools

and materials to permit habit formation.
• Tools and materials should be pre-positioned to reduce
searching.
• Gravity fed bins and containers should be used to deliver the
materials as close to the point of use as possible.
• Tools, materials and controls should be located within the
maximum working area and as near to the worker as possible.
• Materials and tools should be arranged to permit the best
sequence of motions.

WOODGROVE 19
BANK
• ‘Drop deliveries’ or ejectors should be used wherever possible
so that the operator does not have to use his hands to dispose
off the finished work.
• Provision should be made for adequate lighting and a chair of
the type and height to permit good posture should be
provided.
• The height of the workplace and seat should be arranged to
allow alternate standing and sitting.
• The colour of the workplace should contrast with that of the
work and thus reduce eye fatigue.

WOODGROVE 20
BANK
TOOLS AND EQUIPMENT

• The hands should be relieved from ‘holding’ the work piece

where this can be done by a jig, fixture or foot-operated device.
• Two or more tools should be combined wherever possible.
• Where each finger performs some specific movement, as in
typewriting, the load should be distributed in accordance with
the inherent capacities of the fingers.
• Handles such as those on cranks and large screwdrivers should
be designed so as to permit as much of the surface of the hand
as possible to come into contact with the handle. This is
especially necessary when considerable force has to be used on
the handle.
• Levers, crossbars and hand-wheels should be placed so that the
operator can use them with the least change in body position
and the greatest mechanical advantage.

WOODGROVE 21
BANK
 Method Study of
Bottleneck Operation in

CASE STUDY T-shirt Production Line

WOODGROVE 22
BANK
CASE STUDY

• A case study has been carried out at Envoy Textile Limited in Savar
about workload allocation and bottleneck related problem.
• The experimental result shows significant improvement in productivity
and line efficiency as compared to the existing system.
• Here researchers found that in basic T-shirt sewing line 12 types of
different operations have been done. In some process of existing sewing
assembly line, huge bottleneck appeared. This bottleneck operation is
reducing the efficiency of that process. For improving the efficiency,
researchers minimized the bottleneck operation from sewing or
production line using line balancing method.

WOODGROVE 23
BANK
• In the first scenario, overall 18 workers were applied but efficiency was 47% and productivity
was 57 pcs/hr, Side tuck cuff was the most time-consuming process and also the capacity of
Neck Joining process is relatively low.
• In the second scenario, an optimal layout was proposed. It was mainly focused on the Side tuck
cuff and Neck Joining process as these two were the most time consuming of the whole process.
In proposed layout the workloads were well balanced and two more machines added to reduce
the bottleneck problem. Then finally overall 20 workers were applied but efficiency was 77%
and productivity was 94 pcs/hr.

WOODGROVE 24
BANK
METHOD STUDY

In this case study we studied the basic approach of method study:

• Select- We selected T-shirt Production Line to be studied.
• Record- Then we recorded the time taken by each operation in the T-shirt making process using
Multiple Activity Charts and the movement of material, using Flow Diagram.
• Examine- Then, we examined the recorded data and identified bottleneck operation that was,
Side Tuck Cuff and Neck Joining.
• Develop- We developed a method to combat the bottleneck operation, we came up with
Assembly Line Balancing Technique.
• Evaluate- The statistics showed that on Line Balancing the production and efficiency will
increase.
• Define- On the basis of stats, we declared that the Line Balancing technique will be used from
now on for better production.
• Install- The line balancing technique was applied and the efficiency went up to 77% from 47%.
• Maintain- The supervisors need to take care that the same layout of the T-shirt Production Line is
carried out from now, on.
WOODGROVE 25
BANK
 WOODGROVE
BANK

THANK YOU