Ergonomics in the Textile
and Apparel Industries
Introduction
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%
Introduction
Challenges Facing the Industry
Today
Learning Curves of Several Months to
Attain Needed Skill Levels for Many
Jobs
Difficulty in Applying Modern
Automation Technologies to Fabrics
Processing
Ergonomics
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
Textile and Apparel Workers
70% of Sewing Machine Operators Using
Foot Controls Report Back Pain
35% Report Persistent Low Back Pain
25% 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
Textile 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
Illnesses
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 CTDs
Analysis Reveals That 40% ofOperators
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 Lighting
PreciseStitching 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
Seating
Straight Backed Wooden or Metal Chairs
are Typical in the Industry
Chairs Often Lack Cushioning
Chairs Often Lack Adjustable Back
Rests
Chairs Often Lack Height Adjustability
Improved Seating is Readily Available
PsychoSocial 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 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 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
Ergonomics Program
Training forSupervisors and Managers
Awareness Training for Employees
Job Analyses and Implementation of
Controls
Worker Involvement and Participation
Medical Management
Recommended by National Institute of Occupational Safety and Health (NIOSH)
WorkStation Redesign - Sewing
Machines
30” Fixed TableTop Height
Point of Operation Between 4-7” Above
TableTop
Sewing Machine Tilted 11 o Toward Operator
For Jobs of Longer Duration Sewing - Bench
Mounted Arm Rests
Adjustable Chair
Adjustable Foot Rest With Movable Machine
Control
Work 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 Handling
EliminatesHeavy 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 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 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 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 Manufacturing
SignificantlyReduced 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 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 Resources
National Institute for
Occupational
Safety and Health (NIOSH)
800-35-NIOSH
NIOSH Publication: Elements of
Ergonomics Programs, January 1997
Questions and Answers
This program developed by David
Mahone, CNA Insurance
Companies, Chicago IL
Corporate Underwriting Center