INTRODUCTION: Ergonomics is the study of people while they use equipment in specific environments to perform certain tasks. Ergonomics seeks to minimize adverse effects of the environment and way of working upon people and thus to enable each person to maximize his or her contribution to a given job. Every job has a proper working rule to do the job without any physical hazard. Unfortunately, people of our country are not much conscious about this. As a result, musculoskeletal injuries caused by working are common. The majority of these injuries are not accident- related broken bones or strained ligaments. They usually develop over a period because of repeated stress on a particular body part. This condition often ignored until the symptoms become chronic and permanent injury occurs. Knit ware industries are the biggest workplace in our country, where a large number of our population is involved. But, in case of low social status of the labors and optimum gaining tendency in a short period, industry owners do not look after the workers health very much because of plenty and ease of getting labors. But, things are changing now-a- days. The way of looking after the labors is changing. People are now more careful about the health of workers. Purpose of Study The purpose of this project is to find out the ergonomic risk factors in a sewing floor of a garment industry. After analyzing the risk factors like MSDs and environmental risks, to provide the possible solutions. Goals of This Study: Performing qualitative surveys on employees and the tasks they perform to determine the problems Establishing the role of Safety in the garment industry to prevent and control the work related Musculoskeletal Disorders (MSDs) 1
Transcript
INTRODUCTION:
Ergonomics is the study of people while they use equipment in specific environments to perform certain tasks. Ergonomics seeks to minimize adverse effects of the environment and way of working upon people and thus to enable each person to maximize his or her contribution to a given job. Every job has a proper working rule to do the job without any physical hazard. Unfortunately, people of our country are not much conscious about this. As a result, musculoskeletal injuries caused by working are common. The majority of these injuries are not accident-related broken bones or strained ligaments. They usually develop over a period because of repeated stress on a particular body part. This condition often ignored until the symptoms become chronic and permanent injury occurs.Knit ware industries are the biggest workplace in our country, where a large number of our population is involved. But, in case of low social status of the labors and optimum gaining tendency in a short period, industry owners do not look after the workers health very much because of plenty and ease of getting labors. But, things are changing now-a-days. The way of looking after the labors is changing. People are now more careful about the health of workers.
Purpose of Study
The purpose of this project is to find out the ergonomic risk factors in a sewing floor of a garment industry. After analyzing the risk factors like MSDs and environmental risks, to provide the possible solutions.
Goals of This Study:
Performing qualitative surveys on employees and the tasks they perform to determine the problems
Establishing the role of Safety in the garment industry to prevent and control the work related Musculoskeletal Disorders (MSDs)
Increasing awareness of musculoskeletal disorders (MSDs) and the hazards associated with them, and to begin to address potential MSDs through recognition, assessment and control activities
Working place:
A knit wear industry name “URMI group”, located near about Nabisco point, Tejgaon industrial area, Dhaka selected for us as ours work place. We went there to observe and get the information about ergonomic risk factors that cause developing MSDs. Our particular work area was sewing floor of the industry.
Definition Of terms
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Ergonomics:
Ergonomics is a means of improving working conditions and reducing illness at work. Ergonomics attempts to ‘Fit the Job to the Man’ rather than ‘Fit the Man to the Job. It is concerned with the design of systems in which people carry out work and optimization of efficiency, Health, Safety and Comfort of people through better designs of products and work places.(class lecture,8/’11)
Musculoskeletal Disorders (MSD):
Musculoskeletal disorders (MSDs), which is a class of injury that amounts to “wear and tear” on the human body. Disorders rise in the muscles, tendons, ligaments, joints, cartilage, nerves, blood vessels, or spinal discs commonly called as MSDs.
Repetition:
Repetition is the number of a similar exertions performed during a task. A garment worker may lift three boxes per minute from the floor to a countertop; an assembly worker may make 20 units per hour. Repetitive motion has been associated with injury and worker discomfort (Ergo Web, 2009).
Cumulative Trauma Disorders (CTD):
In addition, referred to as repetitive motion injuries, result from excessive use of the hand, wrist, or forearm. Most common CTD's are carpal tunnel syndrome, cubital tunnel syndrome, tendinitis, and tenosynovitis.
Cause for developing MSDs:
There are four major ergonomic risk factors that contribute to the development of musculoskeletal illnesses; awkward postures, excessive forces, high repetitions, and vibration.Awkward postures are extreme body-related positions that increase pressure on muscles, tendons, and nerves, or when the tendons are bunched together and are forced to operate while stretched (Tayyari & Smith, 1997). These postures are most common when employees are bending too far, reaching long distances, and twisting their spines to complete their tasks. When the body is held in an awkward posture, it would seem likely that there is a potential for injury that can affect the workers ability to complete their daily tasks.Force is the amount of physical effort, which is required by the person to perform a task and or maintain control of tools and equipment. The effort depends on type of grip, object weight, object dimensions, body posture, type of activity, slipperiness of object, temperature, the presence of pinching and vibration, duration of the task, and number of repetitions. Activities requiring excessive force can strain muscles and tendons, and hence increase the risk of developing cumulative trauma disorders. When muscle efforts increase due to performing a task, circulation of blood to the muscles decreases, causing the muscles to fatigue quicker.Repetitions are defined as performing the same motions repeatedly. The severity of risk depends on the frequency of repetition, speed of the movement or motion, the number of muscle groups involved, and the required force. Repetitiveness is often influenced by machine or line pacing incentive programs,
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piecework, and unrealistic deadlines. Repeating the same movements repeatedly will eventually fatigue the involved muscles. Frequent movements become much more risky if they are combined with poor postures and excessive forces. However, high frequencies of repetition, even with small forces, can cause or contribute to the development of musculoskeletal disorders.
Symptoms of MSDs:
The symptoms of the MSDs can be felt, but not observe. The symptoms are :1. Pain 2. Discomfort3. Weakness4. Tingling5. numbness
Stages of MSD development:
Common problems
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Stage 1aching and fatiguesymptoms go away with rest
stage 2pain, acing and fatiguesymptoms present at work and homemay interrupt sleep
stage 3pain, achin,fatigue even at restno longer workingsleep disturbence is common.
Figure 1: work station
Work space:
Poor work space for the worker to do their job. Worker cannot move freely for less space. Because of not having, any automated conveying system they have to bent or twist their waist to move the lot to another worker.
Non-automated rail system:
Inflexible system with poor work organization requires operators to manually transport them to another workstation. This is a very awkward and heavy to lift and carry.
Tables related problems:
Condition: Tables are often full garments. Tables are in poor locations, unstable or garments fall off them so operators have to reach to the floor to pick them up.
Height: Sewing tables are not easily adjustable. Tables, which are too high, create elevated shoulder postures and non-neutral elbow and wrist postures.
Size and shape: Some tables are not large enough to support the amount of the garment. Table length is enough, but the width of the table is not sufficient to allocate the garments.
Foot rest: sewing table have no foot rest for the workers.
Chairs:
The chair is a critical piece of equipment for sewing machine operators who work in a seated position. It can have a very large impact on the comfort of the worker and can affect the risk of muscle pain and injury. Operators are provided with very poor chairs such as wooden chairs. These chairs are not adjustable. They provide back support, but worker cannot suppose to benefiter with that and the edge of the seat constricts blood flow at the back of the legs because of a large rounded hump or square edge.
Foot Pedals
Most sewing machine operators use one treadle, which controls the direction and speed of the sewing machine. Some operators use additional smaller pedals that lift the presser foot or cut the thread.Treadles are very rarely in a proper position for the operators. They are either too far forward or too close to the operator. Both problems are bad for the posture of the operator. Treadles are usually too small be comfortably operated by both feet, and some are at a very steep angle. The pedal is usually not in a comfortable position. When only one foot is used the operators rarely have a footrest to support
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the non-working foot. For standing operations the pedals are too high, requiring the operator to balance on one leg, and they cannot be moved to rotate the effort between both legs.
Knee SwitchesOperators use knee switches to control the machine needle. Knee switches are located in a poor position and are hard, creating contact stress on the leg.
Light:
Workstations are too dim. Light sources are not arranged properly and shadows create uneven light across the work surface. Shiny surfaces that reflect light or task lights that shine directly into the operator’s eyes create glare. Lights are not setup at the proper place, so various parts and particles of the machine and other thing make shadow in front of the operator’s sight.
Temperature:
Temperature of the working environment is too hot. There is no proper ventilation system in the floor. Because of gathering too many people at the floor at a time, floor become high tempered and workers sweating all the time. For that reason, the environment is adverse to workers. This over temperature results in high humidity rate.
Data collection:
Data Collection Procedures
1. Observe the entire floor to become familiar with the postures and work practices.
2. Mark up the environmental and postural problems present in the floor.
3. Collect anthropometric measurement from the workers.
4. Interviewing workers to get information’s about their current health condition.
Data collection: We made a standard questionnaire to get the information of the workers.
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Data analysis:
The data collected from the questionnaire is evaluated using the tables on the respective worksheets for each specific workstation. Based on the survey we did a statistical analysis of the collected information and give a graphical presentation of the result. From the graph we get a transparent idea of the development of MSDs at the sewing floor.
Some statistical and graphical image of the current situation of MSDs development is given below:
Participants Basic Work Details:
Survey Questions Number Percentage (%)
As the job highly repetitive, is it monotonous to you?
Never 22 37.3
Sometimes 23 39
Often 11 18.6
Always 3 5.1
Do you have any training or lesson on how to work with safe body posture?Yes 15 25.4
No 44 74.6
Do you follow the lesson while working?
Yes 14 93.3
No 1 6.7
How long you work at your workplace (in hours)?
8 26 44.1
9 2 3.39
10 31 52.54
How long you used to work continuously in your workstation at one sitting (in hours)?Below 1 22 37.3
1-2 19 3.4
2-3 14 3.4
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3-4 2 23.7
4-5 2 32.2
Graphical presentation:
Figure 2: Feeling discomfort in workplace
Yes No0
102030405060708090
100
Figure 3: Feeling pain in body parts
Yes No0
102030405060708090
Figure 4: Treatment was helpful or not
Machine wise workers data analysis:
BodyParts
Single Needle Plain(Sample:20)
MultimachineOperator(Sample: 6)
Packaging Operator(Sample: 5)
QualityInspector(Sample: 4)
Flat LockOperator(Sample: 8)
Over LockOperator(Sample:12)
Iron Man
(Sample: 4)
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X-axis: Frequency
Y-axis: Percentage (%)
X-axis: Remarks
Y-axis: Percentage
X-axis: Remarks
Y-axis: Percentage
Num. % Num. % Num. % Num. % Num. % Num % Num. %
Eye 4 20 1 16.6 2 40 4 100 4 50 4 33.3 2 50
Neck 13 65 5 83.3 4 80 1 25 3 37.5 6 50 0 0
Shoulder Joint
6 30 3 50 4 80 3 75 3 37.5 5 41.7 3 75
Scapula 4 20 0 0 1 20 1 25 2 25 2 16.7 2 50
Arm 3 15 2 33.3 2 40 1 25 2 25 2 16.7 2 50
Elbow Joint
2 10 0 0 3 60 1 25 1 12.5 0 0 1 25
Forearm 1 5 0 0 1 20 1 25 1 12.5 1 8.3 0 0
WristJoint
6 30 4 66.7 2 40 1 25 1 12.5 5 41.7 2 50
Fingers 3 15 2 33.3 1 20 1 25 0 0 1 8.3 1 25
Right UpperBack
11 55 4 66.7 2 40 2 50 2 25 5 41.7 3 75
Left UpperBack
10 50 4 66.7 2 40 1 25 4 50 5 41.7 2 50
Low Back (Waist)
9 45 4 66.7 5 100 1 25 5 62.5 7 58.3 2 50
Thigh 2 10 2 33.3 0 0 1 25 1 12.5 2 16.7 1 25
Knee 2 10 3 50 2 40 1 25 1 12.5 1 8.3 3 75
Calf 2 10 2 33.3 3 60 1 25 1 12.5 1 8.3 1 25
Ankle 6 30 4 67.7 4 80 1 25 0 0 2 16.7 1 25
Foot/ Fingers
4 20 3 50 2 40 3 75 2 37.5 3 25 3 75
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Eye
Neck
ShoulderJ
oint
Scapula
Arm
Elbow Jo
int
Forea
rm
Wris
tJoint
Finge
rs
Right U
pperBack
Left UpperB
ack
Low Back
(Wais
t)Th
igh Knee CalfAnkle
Foot/
Finge
rs0
10
20
30
40
50
60
70
Figure 5: Graphical Presentation of MSDs present in SNL Operators
Eye
Neck
ShoulderJ
oint
Scapula
Arm
Elbow Jo
int
Forea
rm
Wris
tJoint
Finge
rs
Right U
pperBack
Left UpperB
ack
Low Back
(Wais
t)Th
igh Knee CalfAnkle
Foot/
Finge
rs0
102030405060708090
Figure 6: Graphical Presentation of MSDs affected limbs of Multi-machine Operators
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X-axis: MSD affected body parts
Y-axis: Percentage
Y-axis: Percentage
Eye
Neck
ShoulderJ
oint
Scapula
Arm
Elbow Jo
int
Forea
rm
Wris
tJoint
Finge
rs
Right U
pperBack
Left UpperB
ack
Low Back
(Wais
t)Th
igh Knee CalfAnkle
Foot/
Finge
rs0
20406080
100120
Figure 7: MSDs affecting % in limbs of Quality Inspectors
Eye
Neck
ShoulderJ
oint
Scapula
Arm
Elbow Jo
int
Forea
rm
Wris
tJoint
Finge
rs
Right U
pperBack
Left UpperB
ack
Low Back
(Wais
t)Th
igh Knee CalfAnkle
Foot/
Finge
rs0
10203040506070
Figure 8: Graphical Presentation of MSDs Present in Flat Lock Machine Operators
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X-axis: MSD affected body parts
Y-axis: Percentage
Y-axis: Percentage
Result
Major findings:
From the observation and data analysis, we get a clear idea about the rate of MSDs present in the worker.From the observation found some factors that cause developing MSDs in the workers body;The working Space, table, system, chair, light, foot pedal, temperature etc are problematic. Here we try to give some possible solution of the problems that we found at the work place:
Non-automated convey system: moving belt can provide by the company to reduce MSDs to the workers so that they can reach the unfinished garments without bending their body parts.
Tables: Tables should match the height of the sewing table, or be slightly lower if bundles are placed on them. They should be stable and sufficiently large or have raised edges to contain the garments on the table. Use friction tape if the fabric or table is too slippery. Height: A good height for sewing tables is at or slightly above elbow height. The height should be easily adjustable with the press of a button.
Size and shape: Sewing tables can be modified to meet the requirements of specific garments, machines or operators by making the table smaller to allow carts to get close to the sewing machine. Increase the size of the table. This can be helpful for supporting the weight of large garments or for using the sewing table as the input location. Placing raised edges on the table, to help to keep the material on the table.
Chair:
The chairs may have these features for the prevention of MSDs: a stable 4-point base of support; firm cushioning on the backrest and seat pan; the seat can be adjusted in height and tilt quickly and easily; the seat does not have a hump on the front edge; the backrest can be adjusted in height and from front to back; the seat pan is large enough to support the operator but small enough so
that he or she can use the backrest; the backrest does not interfere with the movement of the shoulder blades or
arms; the chair can swivel when operators have to turn sideways frequently; and The chair has castors only where appropriate, and not where it makes
operators slide away from their workstation.
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LIGHT: Ensure there is good general lighting and task lights are provided for operators who desire them or have visually demanding tasks. The task lights should have a “goose-neck” so the light can be directed to the work area. Lampshades should have ventilation holes, but where necessary these can be covered so that the light is not directed through these holes towards the operator.
CONCLUSION
In the end, this project demonstrates that there is ample room for ergonomic improvements in the above garment 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.
REFERENCE:
Tayyari, F, & Smith, J (1997). Occupational ergonomics principles and applications.London: Chapman and Hall.
Chengular, S.N., Rodgers, S.H., & Bernard, T.E. (2004). Kodak's ergonomic design for people atwork. Hoboken, NJ: John Wiley & Sons, Inc ..
Questionnaire A. Participant’s Basic Work Details:
1. Name:
2. Gender: □ Female □ Male
3. Marital Status: □ Married □ Single
4. Height: ft in / m cm 5. Weight: Kg
6. Education: 7.Total Work Experience: Months Years
8. Current Work Position: 9. Current Work Experience: Months Years
10. Last Work Position: 11. Last Work Experience: Months Years
11. As the job is highly repetitive, is it monotonous to you?
□ Never □ Sometimes □ Often □ Always
12. Do you have any training or any lesson on how to work with safe body posture?
□ Yes □ No 12.1 If “Yes”, do you follow it while working?
□ Yes □ No
13. How long you work every day at your workplace? Hours
14. How long you used to work continuously in your workstation at one sitting (in hours)?
□ 1-2 □ 2-3 □ 3-4 □ 4-5
15. What is the rest break frequency at your work? Times per day.
16. What is the rest break duration in each time? Mins / Hours
B. Symptoms Survey:
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Upper Back: 1.Right 2.Left
1Symptoms SymbolBurning BCrampingCNumbnessNOnly PainPSwelling with PainSPWeaknessW
2Frequency SymbolFrequently FOccasionally ORarely RSometimes ST
3Intensity SymbolSlight SLModerate MSever SV
1. Do you feel discomfort while working here?
□ Never □ Sometimes □ Often □ Always
2. When did you first notice your discomfort? Months Years ago.
3. Do you feel pain (in body parts) or burning/itching (in eyes) while working or after working in your body?
□ Yes □ No
3.1 If “Yes” please carefully indicate in the body area shown below:
Body Parts Symptom1 Frequency2 *Intensity3
1. Eye2.Neck3.Shoulder joint4.Scapula5.Arm6.Elbow joint7.Forearm8.Wrist joint9.Fingers10.Right upper back
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11.Left upper Back12.Low back (waist)13.Thigh14.Knee15.Calf16.Ankle17.Foot/ Fingers
*Intensity: 1.Slight- pain and fatigue noticed at the end of the task or end of day; daily living unaffected. 2. Moderate- pain and fatigue noticed throughout the day; daily living minimally affected. 3. Sever- pain and fatigue even during rest and after work, or any numbness or tingling experienced, daily living restricted.
4. When did you first notice the problems? Months Years ago.
5. Have you taken any medical treatment for these problems?
□ Yes □ No
5.1 If “Yes”, did the treatment help you to reduce the pain?
□ Yes □ No
6. Have you taken leave for these problems?
□ Yes □ No
6.1 If “Yes”, how many days you have taken as leave?
□ 1-2 □ 3-5 □ 6-10 □ More than 10 days
7. Have you suffered from any accident in your life that caused injuries in your body?
□ Yes □ No
7.1 If “Yes”, how many years ago and where (at workplace or elsewhere)?
□ 1-2 □ 3-5 □ 6-10 □ More than 10 years
□ At Workplace □ Elsewhere 7.1.1 If at workplace then what type of work you were doing at that Ans.
7.2 Where (which body part) did you get injury during the accident? Ans.
7.2 Does the pain recur sometimes or get cured completely?
□ Recur (after months/ years approximately) □ Cured completely.
8. Do you work (household) at home after returning from you workplace?
□ Yes □ No
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8.1 If “Yes”, how long you work at home (in hours)?
□ 1-2 □ 2-3 □ 3-4 □ More than4 hours
9. How long you sleep at night? Hours
10. What you do at your holidays: □ Do the normal household works for hours/day□ Take rest for hours/day□ Do extra job (for earning money) for hours/day
