The document discusses the importance of ergonomics in apparel factories. It notes that workers in apparel factories often perform repetitive tasks in awkward postures that can lead to injuries over time. Specifically, it examines problems in cutting, spreading, and assembly departments that may compromise worker safety. It provides examples of musculoskeletal issues reported by textile workers and discusses the costs to businesses when ergonomics is not properly implemented, such as increased injuries, medical costs, absenteeism, and turnover. The document emphasizes that ergonomics aims to prevent work-related injuries by addressing risk factors like force, repetition, posture, and vibration.
The document discusses the importance of ergonomics in apparel factories. It notes that workers in apparel factories often perform repetitive tasks in awkward postures that can lead to injuries over time. Specifically, it examines problems in cutting, spreading, and assembly departments that may compromise worker safety. It provides examples of musculoskeletal issues reported by textile workers and discusses the costs to businesses when ergonomics is not properly implemented, such as increased injuries, medical costs, absenteeism, and turnover. The document emphasizes that ergonomics aims to prevent work-related injuries by addressing risk factors like force, repetition, posture, and vibration.
The document discusses the importance of ergonomics in apparel factories. It notes that workers in apparel factories often perform repetitive tasks in awkward postures that can lead to injuries over time. Specifically, it examines problems in cutting, spreading, and assembly departments that may compromise worker safety. It provides examples of musculoskeletal issues reported by textile workers and discusses the costs to businesses when ergonomics is not properly implemented, such as increased injuries, medical costs, absenteeism, and turnover. The document emphasizes that ergonomics aims to prevent work-related injuries by addressing risk factors like force, repetition, posture, and vibration.
The document discusses the importance of ergonomics in apparel factories. It notes that workers in apparel factories often perform repetitive tasks in awkward postures that can lead to injuries over time. Specifically, it examines problems in cutting, spreading, and assembly departments that may compromise worker safety. It provides examples of musculoskeletal issues reported by textile workers and discusses the costs to businesses when ergonomics is not properly implemented, such as increased injuries, medical costs, absenteeism, and turnover. The document emphasizes that ergonomics aims to prevent work-related injuries by addressing risk factors like force, repetition, posture, and vibration.
In preparation of our assignment, We had to take the help and
guidance of some respected persons, who deserve our deepest gratitude. As the completion of this assignment gave us much pleasure, We would like to show our gratitude Mr. Kamaljeet Singh, Apparel Production, Planning and Control Faculty, of Nift Kangra, for giving us good guideline for assignment throughout numerous consultations. We would also like to expand our gratitude to all those who have directly and indirectly guided us in making this assignment.
We also thank Nift Kangra for giving us such an opportunity to
explore more with constant learning. However, it would not have been possible without the kind support and help of many individuals and institution. Our thanks and appreciations also go to our classmates in developing the assignment and people who have willingly helped us out with their abilities. ERGONOMICS Ergonomics is the study of people in their working environment. It is a field of study that deals with the interaction between man and the total working environment, such as atmosphere, heat, light and sound, as well as tools and equipment of the workplace.
The main goal of ergonomics is to increase productivity and efficiency on one hand and at the same time to make the employees work under humane conditions and within the comfort limits on the other hand.
IMPORTANCE OF ERGONOMICS
An ergonomist designs or modifies the work to fit the worker, not the other way around. The goal is to eliminate discomfort and risk of injury due to work. In other words, the employee is the first priority in analyzing a workstation. In the garment industry, workers spend most of their time carrying out repetitive activities in awkward postures. If one does not sit properly, take regular breaks, and also use correctly positioned furniture and equipment, they become vulnerable to pain and discomfort. Injuries and muscle pain affecting the wrists, shoulders, neck and back are common problems for workers in the garment industry. The worker is forced to work within the confines of the job or workstation that already exists. This may require employees to work in awkward postures, perform the same motion over and over again, or lift heavy loads – all of which could cause work-related musculoskeletal disorders. Ergonomics aims at preventing injuries by controlling the risk factors such as force, repetition, posture, and vibration that can cause injuries to develop.
Some fundamental ergonomic principles that should be followed in
workplaces are: 1. Use proper tools, 2. Keep repetitive motions to a minimum, 3. Avoid awkward posture, 4. Use safe lifting procedures, 5. Get proper rest PROBLEMS FACED BY DIFFERENT DEPARTMENTS IN APPAREL INDUSTRY CUTTING DEPARTMENT Loading by hand. Lots of fabric lifted by hand are heavy and create a substantial risk of lower back injury.
Loading with a fixed assist
accompanying the spreader. Bolts are rarely in the proper location to be picked up by the fixed assist- operators have to maneuver the bolt by hand.
Loading with a movable assist
Spreaders that require the bolt of fabric to be threaded with a spreader bar – some bars are very heavy. Bolts located on the floor require the operator to adopt a stooped or squat posture to thread the bar. When no spreader bar is required the operator has to lift one end of the bolt at a time to attach the hoist.
SPREADING DEPARTMENT Spreading by hand. Long reaches are required to cut across the width of the fabric each time a layer is completed or flaws are removed from the fabric.
Manual spreading Operators have the long reach across the table to cut the fabric and they have to manually pick up weights to hold the fabric down each time a layer is completed before spreading the fabric in the other direction. Automated spreading. Operators either ride on a platform or walk beside the automatic spreader as it moves along the table. Operators often have to smooth the fabric while it is being spread. The table is often too low and operators have to bend their backs while smoothing. This is a risky posture when maintained for extended periods of time
ASSEMBLY DEPARTMENT Attachments to the sewing table. Wooden bars attached to the sewing table are used as the supply location. These bars are sometimes located too far from the operator, are too small or allow the garments to slip off them.
Rolling carts. The carts are very heavy and the shelving units are low. Wheels are frequently in very poor repair and/or have a build-up of thread on them. This makes the carts very difficult to maneuver.
Automated stackers Stackers deposit the garments at a low location that requires someone to bend down to pick them up to move them on to the next workstation.
Height of the Tables
Sewing tables are not easily adjustable. Tables that are too high create elevated shoulder postures and non-neutral elbow and wrist postures. Tables that are too low cause the operator to lean forward and flex his or her neck.
Size and shape
Tables aren't large enough to support the weight of the garment. Other tables are too large and get in the way of easy pickup and deposit, particularly when using automated transport systems.Table angles are also not comfortable at times.
Leg room Sewing machine operators have limited legroom because of drawers and/or trash chutes attached to the underside of the table. Illness and injuries among textile workers according to a research conducted: 70% of sewing machine operators using foot controls report back pain. 35% report persistent lower back pain. 25% have suffered a compensable cumulative trauma disorder (CTD). Work in the garment factories is repetitive 81% reported CTDs to the wrist. and monotonous requiring strong visual 14% reported CTDs to the elbow. demands, improper postural requirements, 5% reported CTDs to the shoulder. involving long hours sitting or standing in 49% of workers experience neck pains. one position. Absenteeism increases as working conditions worsens. The leading issues of which employees, Loss of worker force due to injuries or who worked for many years in the garment high turnover is associated with working sector, complain are back, waist, shoulder conditions. pain, burn and pain in hands, arms and Hand sewing and trimming are stressful elbows, neck flattening, musculoskeletal to upper limbs. problems, pain in the feet and legs, eye Stitching tasks are associated with pain problems. in the shoulders, wrists, and handsIroning by hand is associated with elbow pain. Garment assembly tasks are associated with CTDs of the hands and wrists. Foot operated sewing is associated with pain in the back COST OF BAD ERGONOMICS The apparel industry has found that the cost of piecework can be high, for workers who suffer repetitive motion injuries and employers who bear high workers’ compensation costs.
EXAMPLE: The Owenby Company
(Blairsville, Georgia), a small contract T- shirt factory, experienced that over a four- year period, worker’s compensation costs for the nearly 300 employees tripled, and the number of injuries increased eightfold. Worker’s compensation premiums skyrocketed 250 percent in just three policy periods
LOSSES FROM THE FAILURE TO APPLY CONSTRUCTIVE
ERGONOMICS: • Lower production output • Increased lost time • Higher medical and material costs • Increased absenteeism • Low-quality work • Injuries, strains, fatigue • Increased incidence of accidents and errors • Increased labour turnover • Less spare capacity to deal with emergencies • Reduced productivity • Reduced competitiveness REFERENCES: https://www.homesciencejournal.com/archives/2018/vol4issue3/PartF/4-3-59-898.pdf https://www.iwh.on.ca/sites/iwh/files/iwh/tools/ergo_handbook_clothing_2001.pdf https://docs.google.com/document/d/1fPrXpLdquA0OkM2yc8bXvVccN4dgR- aw10J8McHXGgs/edit?usp=sharing https://core.ac.uk/download/pdf/43177848.pdf
