Ergonomics in stitching

By- Suraj Kedia

What is Ergonomics?
Ergonomics is a topic that affects us all; yet few
of us have a good understanding of what the
term actually means or realize how it affects us.
Ergonomics is a science that focuses on
designing a job for the worker.
Ergonomics aims at preventing injuries by
controlling the risk factors such as force,
repetition, posture and vibration that can cause
injuries to develop.
Why ergonomics in stitching?
Research shows that sewing machine operators face
a substantially higher risk of muscle pain and injury
than workers in other jobs.
Studies also show that the frequency of persistent
neck and shoulder injuries increases with years of
employment.
One report found that sewing machine operators
experience as many cases of repetitive strain injuries
as data entry operators and secretaries combined.
These injuries lead to long-term health effects.
Components for ergonomic assessment
in sewing
Supply and removal of garments
Setting up material
Manipulating material
Stitching material
Sewing table
Chair
Floor surface
Foot pedals
Lighting
Hand tools
Work organization
Supply and removal of garments

COMMON PROBLEMS-
Boxes-Large boxes that are low to the ground create
an awkward reach and bend during each pickup.
Tables-Tables are in poor locations, unstable or
garments fall off them so operators have to reach to
the floor to pick them up.
Rolling carts- Carts are large and very low creating
an extended reach and bend when picking up
unfinished garments at the bottom of the cart.
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.
 Non-automated rail system-Inflexible system with poor work
organization requires operators to manually remove full
hangers from the rail to transport them to another
workstation. This is a very awkward and heavy lift and carry.
Automated rail system-Pieces not delivered to the workstation
at an ideal height require the operator to reach, bend and/or
twist to reach the garment. Sewing tables larger than
necessary do not allow the operator to get close to the hanger.
A lot of force is required to hook and unhook the garments
from the hangers. Hangers fall off the rail and the operators
have to lift them back on. Buttons that control the movement
of the hangers are often too far away from the operator or in
awkward locations.
POSSIBLE SOLUTIONS-
Boxes-Place small boxes on a platform to supply the operator with
the necessary pieces at a good height and within easy reach.
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.
Rolling carts. Make sure the cart is suitable for the task. A simple
but effective cart for lightweight garments is a small wire frame on
wheels with a shallow canvas liner. The top of the cart must be at the
height of the sewing table. Eliminate the problem of thread in the
wheels through regular maintenance or use spherical castors that do
not get filled with thread.
 Non-automated rail system-A good method is for the
operators to work on a raised platform so they can work from
the high rail without removing garments from the hanger or
having to reach above shoulder height for them.
Automated rail system-A good practice is to leave the
garments attached to the hanger while performing the
assembly task. Locate hangers directly beside the worker or
sewing table. The table should be as small as possible to allow
the garment to be close to the operator. Place a low table
under the hanger to help support heavy garments and reduce
the reach to lift them up from ground level. Place the controls
for the system close to the common working position of the
hands without interfering with the task, or integrate controls
into foot controls.
Setting up material
COMMON PROBLEMS-
When setting up material for stitching, workers
may have to flex or bend their necks to view the
position of the fabric.
POSSIBLE SOLUTIONS-
Use automatic feeding and set up, which
eliminates the operator using awkward postures.

Provide proper lighting

Manipulating material
COMMON PROBLEMS-
While manipulating fabric,
employees repeatedly use a
forceful pinch grip between
the thumb and index finger.
POSSIBLE SOLUTIONS
Use friction-increasing aids on
fingers to reduce amount of
force exerted in the pinch grip.

Analyze tasks to determine

force requirement and use
job/task rotation through
tasks not requiring pinch grip.
Stitching material
COMMON PROBLEMS-
Employees push fabric
through the sewing machine,
which may require extending
arms, bending at the waist,
and applying force
POSSIBLE SOLUTIONS-
Use height adjustable tables ,
which, when properly adjusted,
may reduce arm extension and
bending at the waist.

Allow the machine to pull the

fabric through rather than
having the operator push the
fabric.

Reduce the distance between the

operator and the machine.
Sewing Table
COMMON PROBLEMS-
Height-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-Some tables are not 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. Many tables are not the appropriate shape for the
job.
Table angle-Almost all sewing tables are flat. Flat sewing tables do
not maximize visibility and compromise the posture of the upper
extremity and neck.
Leg room. Sewing machine operators have limited legroom because
of drawers and/or trash chutes attached to the underside of the
table.
Possible solutions-
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. Putting an addition on
the table to 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.
 Table angle-A few sewing tables that were tilted
10 to 25 towards the operator. This tilt
improves visibility of the task and helps to keep
the neck in a more upright position while having
the table at an appropriate height for the upper
extremity.
Leg room-Make sure that operators have
sufficient leg room. Drawers and trash chutes
either should be not present or in a location that
does not hinder leg room.
Chairs
COMMON PROBLEMS-
Operators are provided with very poor chairs. These chairs are not
adjustable. They provide no cushioning or back support and the
edge of the seat constricts blood flow at the back of the legs because
of a large rounded hump or square edge.
Some plants provide slightly better chairs that have some height or
back adjustment capabilities but they cannot be adjusted quickly
and easily and do not provide sufficient back support.
Some plants purchase chairs that they believe are ergonomically
correct, but they do not meet the needs of the operators. Common
problems that occur when buying ergonomic chairs are that one
individual selects the chair and it does not fit all or even most
operators, and it is not right for all tasks. For example, the chair
may have castors or may swivel when this is not right for the job.
 Often the seat pan is too large, resulting in the
backrest not touching the back of the operator.
The seat pan may have an uncomfortable hump,
causing the operator to sit on the front edge of
the seat and not use the backrest.
Individuals are not instructed in how to use the
chairs properly. Without proper training the
many benefits of ergonomic chairs are lost.
POSSIBLE SOLUTIONS-
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
The chair has castors only where appropriate, and not where
it makes operators slide away from their workstation.
Foot pedals
COMMON PROBLEMS-
Peddles 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.
Peddles are usually too small to 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 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.
POSSIBLE SOLUTIONS-
Increase the size of the peddles by placing a thin
wooden board over the surface of the pedal.
If only one foot is being used, a footrest must located
at the same height and angle as the peddle.
Pedals for standing operators must be close to the
floor and allow the operator to support her or his
body weight over both feet.
The pedal could be moved so that the operator could
rotate between activating the pedal with her or his
right or left foot.
Knee switches
COMMON PROBLEMS-
Knee switches are located in a poor position and
are hard, creating contact stress on the leg.
POSSIBLE SOLUTIONS-
Place the knee switch so that it rests very close to
the leg, just above the knee, and is well padded.
Hand controls
COMMON PROBLEMS-
Controls are too far from the operator.
Requires excessive force and unnatural direction
to activate.
POSSIBLE SOLUTIONS-
Ensure controls are located in a convenient
position without being in the way.
Controls should be activated with a light touch
applied at multiple angles.
Floor surface
COMMON PROBLEMS-
Operators stand for extended periods of time on
hard surfaces.
POSSIBLE SOLUTIONS-
Provide standing operators with good quality anti-
fatigue mats that cover the entire working area.
Provide operators with a footrest and a sit-stand
stool to help relieve the stress on the feet, legs and
back.
Allow operators to rotate between sitting and
standing work positions.
Lighting
COMMON PROBLEMS-
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 operators eyes create glare.
POSSIBLE SOLUTIONS
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.
Scissors
COMMON PROBLEMS-
Large, heavy scissors are used for trimming threads and
are held by the blade to provide accuracy.
Operators cut through several layers of fabric with
scissors that are too small and do not provide enough
leverage.
Scissor handles are narrow and create contact stresses.
Scissors are dull and require excessive force to operate
POSSIBLE SOLUTIONS-
Operators should have appropriate scissors for the task
such as small, light clippers or a finger cutter to trim
thread, and long scissors that provide leverage for
cutting through several layers of fabric.
Work Organization
COMMON PROBLEMS-
Assembly tasks are very repetitive and provide the
operators with little opportunity for rest.
Many operators perform only one operation with no job
rotation.
The repetitive nature of the job is made worse by
automated delivery systems or by other workers
delivering unfinished garments to the operators.
Workstation adjustment policies are not very effective
because of lack of training of both the operators and the
individuals responsible for the adjustments.
Workplaces have no limit to bundle sizes and they
sometimes are much too large.
POSSIBLE SOLUTIONS-
Organize work so that operators get up from
their workstation to pick up their next work
order.
Repetitive strain can be reduced when operators
assemble large parts or full garments. This
decreases repetition and increases variability
and skill.
Set reasonable limits for bundle sizes.
References
https://www.osha.gov/SLTC/etools/sewing/stit
ching.html
http://www.wsps.ca/WSPS/media/Site/Resourc
es/Downloads/ergonomics_handbook.pdf?ext=.
pdf