Ergonomics in the Textile Ergonomics in the Textile and Apparel Industriesand Apparel Industries

IntroductionIntroduction

Challenges Facing the Industry Today:Competition From Overseas

Companies With Access to Inexpensive Labor

Shortage of Available US Textile Workers

Annual Turnover Rates Ranging From 30% to Over 100%

IntroductionIntroduction

Challenges Facing the Industry TodayLearning Curves of Several Months to

Attain Needed Skill Levels for Many Jobs

Difficulty in Applying Modern Automation Technologies to Fabrics Processing

ErgonomicsErgonomics

Improving Ergonomic Conditions Can Improve Productivity and Safety - Enhance Competitiveness

Reduce Worker Compensation Costs Provide More Reliable Workforce May Include Allocating High Risk Jobs to

Machines Where Possible (They Will Be Going Overseas Anyway)

Injuries and Illnesses Among Injuries and Illnesses Among Textile and Apparel Workers Textile and Apparel Workers

70% of Sewing Machine Operators Using Foot Controls Report Back Pain

35% Report Persistent Low Back Pain25% Have Suffered a Compensable

Cumulative Trauma Disorder (CTD)81% of CTDs Were to the Wrist

14% of CTDs to the Elbow

5% of CTDs to the Shoulder

Injuries and Illnesses Among Injuries and Illnesses Among Textile and Apparel WorkersTextile and Apparel Workers

49% of Workers Experience Pain in the Neck

Absenteeism Increases as Working Conditions Worsen

Loss of Workers Due to Injuries or Turnover is Associated With Working Conditions

Tasks Associated With Injuries and Tasks Associated With Injuries and IllnessesIllnesses

Hand Sewing and Trimming are Stressful to All Upper Limbs

Stitching Tasks are Associated With Pain in the Shoulders, Wrists, and Hands

Ironing 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

Static Postures and CTDsStatic Postures and CTDs

Analysis Reveals That 40% of Operators at Sewing Machines Stoop Forward > 20o Throughout the Machine Cycle

60% Tilt Their Heads Forward > 20o Throughout the Machine Cycle - Why?Visual Demands of the Work

Geometry of the Work Station

Inadequate Seating

Postural Stress and LightingPostural Stress and Lighting

Precise Stitching Tasks are Visually Demanding

Thread and Fabric Often Offer Little or No Visual Contrast

36% of Operators Feel Lighting is Inadequate Surveys Found Light Levels at Less Than 60%

of Recommended Levels Operators Lean Forward to See Their Work

SeatingSeating

Straight Backed Wooden or Metal Chairs are Typical in the Industry

Chairs Often Lack CushioningChairs Often Lack Adjustable Back

RestsChairs Often Lack Height AdjustabilityImproved Seating is Readily Available

PsychoSocial ConsiderationsPsychoSocial Considerations

Psychomotor Demands are High (Speed, Accuracy, Coordination)

Positive Attitudes Toward Work are Inversely Related to Increased Monotony and Fatigue

Positive Attitudes Toward Work are Directly Related to Job Satisfaction

Work OrganizationWork Organization

As Many as 100% of Piecework Operators in High Manipulation Jobs Have Symptoms of CTDs

Workers in Piecework are 4 Times as Likely to Develop Severe Disabilities as Hourly Workers

Workers in Piecework are 9 Times as Likely to Develop Arthritic and Osteoarticular Disorders as Hourly Workers

As Duration of Employment in Piecework Increases, So Does Severe Disabilities

Duration of ExposureDuration of Exposure

Machine Operators Experience Cumulative Damage to the Neck and Shoulders Over Time

Risk for Persistent Neck and Shoulder Pain Increases With Years of Employment as a Machine Operator

Work for More Than Eight Years as Machine Operator Increases Risks For Neck and Shoulder Pain

Solutions - A Comprehensive Solutions - A Comprehensive Ergonomics ProgramErgonomics Program

Training for Supervisors and ManagersAwareness Training for EmployeesJob Analyses and Implementation of

ControlsWorker Involvement and ParticipationMedical Management Recommended by National Institute of Occupational Safety and Health (NIOSH)

WorkStation Redesign - Sewing WorkStation Redesign - Sewing MachinesMachines

30” Fixed TableTop Height Point of Operation Between 4-7” Above

TableTop Sewing Machine Tilted 11o Toward Operator For Jobs of Longer Duration Sewing - Bench

Mounted Arm Rests Adjustable Chair Adjustable Foot Rest With Movable Machine

Control

Work EnhancementsWork Enhancements

Foam Padded Edges to Sharp Table Edges Provide Cloth Upholstered Adjustable Chairs Angle Packing Boxes to Workers With Tilt

Equipment Provide Anti-Fatigue Matting for Standing

Workers Improved Lighting Require Rest Periods Job Rotations

Automated Materials HandlingAutomated Materials Handling

Eliminates Heavy Lifting by Operators or “Bundle Boys”

Uses Pre-Programmed Hanging Conveyor Moves Only One or a Few Work Pieces Per

Hanger Computer Controlled - Movement Tracked by

Bar-Coded Hangers and Series of Scanners Delivers Work to Queue Near Operator

Automated Materials HandlingAutomated Materials Handling

Strong on Pre-Programmed Use But Weak on Flexibility (Short Term Changes, etc.)

Technology is Rapidly Improving Future Models Will Direct More Work to the

Queues of the Most Productive Workers and Less to Slower Workers or Beginners

Modular Manufacturing ConceptModular Manufacturing Concept

Conventional Textile/Apparel Industries Use the Progressive Bundle System - Each Operator is Assigned to a Single Operation

In Modular Mfg. a Complete Garment is Produced in a Modular Cell

Cells May Have 10 Operators and 20 Machines Operators Are Not Assigned to a Single

Operation But Move Between Workstations

Modular Manufacturing ConceptModular Manufacturing Concept

Teams of Operators are Responsible for Work Planning and Management, Product Quality, etc.

Employees are Empowered - Boosts Morale A Variety of Motions are Used by Each

Operator - Reduces Risk for CTDs and Relieves Static Postures

Can Be Reconfigured Rapidly, Providing Great Flexibility

Modular ManufacturingModular Manufacturing

Significantly Reduced Absenteeism Necessitates Better Ergonomic Designs of

Workstations to Accommodate Different Operators

Many Operations Converted to Standing Workstations Instead of Seated Workstations

Employees Paid on a Group Incentive System

Additional ResourcesAdditional Resources

American Textile Manufacturers Institute (ATMI) Washington DC

ATMI Quest for Best in Safety and Health Program

Must Have Comprehensive Program to Join Must be Willing to Interact With Other

Members Companies Nearly Half of ATMI Member Companies

Participate

Additional ResourcesAdditional Resources

National Institute for Occupational Safety and Health (NIOSH)

800-35-NIOSHNIOSH Publication: Elements of

Ergonomics Programs, January 1997

Questions and AnswersQuestions and Answers

This program developed by David This program developed by David Mahone, CNA Insurance Mahone, CNA Insurance Companies, Chicago ILCompanies, Chicago ILCorporate Underwriting Center