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Abstract
This study was conducted in Iranian carpet industry to determine the prevalence of upper limb problems associated with hand tools
design, investigate the design of hand tools currently used in carpet weaving operation, and design/redesign the tools based on
anthropometric dimensions and ergonomic principles. This study consisted of two phases. In the first phase, 862 weavers from three
Iranian provinces participated. A questionnaire consisting of personal details, Nordic Questionnaire for upper limbs and a table for
anthropometric dimensions of hand was used to collect the required data. In the design phase, the study focused on designing/redesigning
the weaving comb, knife and scissors as the most common tools in carpet weaving operation. Based on the first phase results, three
prototypes of the hand tools were made in this phase. Usability test was conducted to assess comfort and applicability of the designed
hand tools and the weavers’ perceptions. Ten experienced weavers participated in this test. Statistical analyses revealed significant
differences between the scores of the old and the new designed tools. There was a significant preference towards the comfort and
applicability of the prototypes (po0.01). The new ergonomically designed weaving hand tools were found to be applicable and
acceptable by the carpet weavers.
Relevance to industry
In hand-woven carpet industry as a small-scale industry, hand tools are widely used. As extensive use of hand tools may play an
important role in the development of upper limb musculoskeletal disorders (MSDs), ergonomic improvements in the carpet hand tools
may promote health and safety among carpet weavers.
r 2007 Elsevier B.V. All rights reserved.
Keywords: Carpet weaving; Hand tools; Ergonomic design; Upper limbs musculoskeletal disorders
0169-8141/$ - see front matter r 2007 Elsevier B.V. All rights reserved.
doi:10.1016/j.ergon.2007.03.005
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582 M. Motamedzade et al. / International Journal of Industrial Ergonomics 37 (2007) 581–587
1993). Ergonomically well-designed hand tools may workshops in rural and urban districts of nine cities in
reduce the risk of occupational injuries of the upper limbs. three Iranian provinces including Eastern Azarbayejan
They also provide comfortable work for the users and give (north–west of Iran), Isfahan (central of Iran) and Kerman
high product quality to the consumers (Sperling et al., (south–east of Iran) were surveyed and weaving hand tools
1993). were studied. In each province, up to 300 weavers were
Carpet hand weaving is a common practice in different randomly selected from the corresponding list of work-
countries such as Iran, China, Turkey, India, Pakistan, shops. Totally, 862 weavers participated in this phase of
Russia, Egypt, Nepal and Afghanistan where intense use of study. A questionnaire was applied to collect required data
hand tools is observed (Choobineh et al., 2004a). Upper from each weaver. The questionnaire consisted of three
limbs problems are prevalent as work-related MSDs parts including; (a) personal details, (b) Nordic Muscu-
among weavers. Kutluhan et al. (2001) believed that loskeletal Questionnaire for upper limbs (Kuorinka et al.,
hand-made carpet weavers were exposed to varying degrees 1987), and (c) a table for anthropometric dimensions of
of repetitive and forceful hand and wrist motions with non- hand.
ergonomic hand tools and they seemed to be at increased All workshops were visited and the questionnaires
risk of developing upper limbs musculoskeletal symptoms were completed by interview. Upon questionnaire comple-
and carpal tunnel syndrome (CTS). They concluded that tion, anthropometric dimensions of weavers’ hands were
weaving was a high-risk profession for upper extremity measured with direct method using a digital caliper by
repetitive strain and CTS. Radjabi declared that constant trained field researchers. Necessary data on weaving
tying of knots with non-ergonomic hand tools might result hand tools design and application in carpet weaving
in swollen finger joints, arthritis and neuralgia, causing operation were provided by photography and videotaping
permanent deformation of the fingers (Radjabi, 1983). techniques.
Researches have proved that in weaving operation because
of continuous use of wrists, fingers and repetitive move- 2.2. Phase 2: hand tool design
ments, the risk of wrist and hand soft tissue, particularly
median nerve, injuries are high (Senveli et al., 1987; Tan In the design phase, based on the results of the first
and Tan, 1998; Budak et al., 2001). phase, designing/redesigning weaving comb, knife and
In carpet weaving operation, more than 10 different scissors as the most commonly used hand tools in carpet
kinds of hand tools are applied among them weaving weaving operation were in central attention. In this phase,
comb, knife and scissors are the most commonly used. the following procedure was followed:
Basically, these are cheap tools made by blacksmiths using
traditional and primitive technology from unsuitable Providing a collection of carpet weaving hand tools
materials and workmanship that noticeably contribute to currently used in weaving operation.
accidents. They are traditionally designed and no ergo- Studying carpet weaving hand tools during work
nomics principle is applied in their structures (Choobineh for considering design/redesign requirements and deter-
et al., 2004b). mining their specifications including weight, texture,
As the use of hand tools may play an important role in handle shape and hand posture during hand tools
the development of disorders and accidents, it is obvious application.
that improvements in the design of hand tools are essential Developing new models of hand tools according to hand
for promoting professional users’ health, particularly anthropometric characteristics of the weavers and
where there is intensive exposure. ergonomic design principles.
As given above, the present study was conducted in Making prototypes.
Iranian carpet industry to determine the prevalence of Testing the prototypes based on a usability test
upper limb problems associated with hand tools design, protocol.
investigate the design of hand tools currently used in carpet Redesigning the prototypes regarding the results of
weaving operation and, if necessary, redesign the tools usability test.
based on anthropometric characteristics of weavers’ hands
and ergonomics principles. Handles were found to be the critical components of the
carpet weaving tools, particularly for weaving combs and
2. Materials and methods knives. For designing handle shape and length, the hand
anthropometric database and weaving practice were the
This study consisted of two phases, which are described basic considerations.
separately. Design principles: Physical factors taken into
consideration in developing new models are described
2.1. Phase 1: field study below:
In this phase, weavers’ individual characteristics and For greatest comfort of use and least stress, the tool
upper limb musculoskeletal symptoms in active weaving handle should be oriented so that, while working, the
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M. Motamedzade et al. / International Journal of Industrial Ergonomics 37 (2007) 581–587 583
hand and the forearm are aligned. Since the shape of the The data on weavers’ perceptions were statistically
tool handle will affect the posture used to hold it, the tested to determine differences between the traditional
shape of the handle is a primary factor which can be and new tools. Perceptions were tested by Wilcoxon
used to reduce or eliminate fatigue in the user (Winston signed-rank test. The level of significance for statistical
and Narayan, 1993). tests was 0.05. Statistical analyses were performed using
The major muscles, which flex the fingers and generate SPSS 10.
grip force are located in the forearm. These muscles have
long tendons that span the wrist joint. Thus, the 3. Results
gripping capability of the fingers is affected by the
position of the wrist. Frequent use of hand tools with 3.1. Phase 1
the wrist in a bent position can cause inflammation,
chronic pain, and possible permanent injury both to Table 1 shows the personal characteristics of the carpet
synovial sheats, protecting the tendons of the wrist and weavers studied in three provinces. The majority of
the median nerve passing through the wrist (Tichauer, weavers were female (74%). Table 2 presents the pre-
1966). valence of MSDs symptoms in both dominant and non-
The cross-sectional configuration of the tool handle dominant upper extremities in the upper limbs of the
directly affects the operator’s performance and health. weavers during the last 12 months. Shoulder, wrist, arm,
The forces generated during use should be distributed elbow and fingers were found to be the most commonly
on as large a pressure area of the palm as possible affected regions among the weavers.
(Winston and Narayan, 1993). An anthropometric database (Table 3) was established
Recesses such as finger grooves should not be provided for hand dimensions of the weavers.
because of the wide variations in finger anthropometry
in the population. In particular, a person with large
fingers may create compressive forces on the lateral 3.2. Phase 2
surfaces of the fingers, which are areas abundant in
superficial nerves and veins (Winston and Narayan, Based on ergonomics hand tool design principles, and
1993). hand anthropometric dimensions of the weavers, proto-
If a tool has a short handle that does not span the types for weaving comb, knife and scissors were developed.
breadth of the palm, high forces are created at the center The details of design process are presented below.
of the palm. Thus, the tool handle should be designed to
extend beyond the hand when gripped (Winston and
Table 1
Narayan, 1993).
Some personal details of the carpet weavers studied in three Iranian
Sharp edges and corners may cause cuts, bruises, or provinces (n ¼ 862)
abrasions. Hence, one should seek to eliminate such
hazards by rounding edges and corners with as large a Age (years) Mean (SD) 36 (14.8)
Min–max 15–82
radius as possible.
Weight (kg) Mean (SD) 58.7 (11.5)
Min–max 28–100
Prototype testing: Usability test was conducted to assess Height (cm) Mean (SD) 159 (8.7)
comfort and applicability of the designed hand tools and Min–max 137–190
the weavers’ perceptions. Five experienced male and five Weaving experience (years) Mean (SD) 21.2 (15.4)
experienced female weavers, having mean age 29.7 years Min–max 1–50
Daily working hours (h) Mean (SD) 7.5 (2.1)
[SD ¼ 7.4], mean weight 65 kg [SD ¼ 7.3], mean stature Min–max 1–13
167.8 cm [SD ¼ 4.2], and mean weaving experience six
years [SD ¼ 5.2] participated in this stage. In the usability
study, the hand tools evaluation checklist, developed by
Dababneh et al. (2004) was applied and the related scores Table 2
were calculated (maximum score ¼ 100). The checklist was Frequency of reported musculoskeletal symptoms in both dominant and
non-dominant upper extremities of the carpet weavers during the 12
modified according to carpet weaving hand tools features months prior to the study (n ¼ 862)
(see Appendix A).
In this stage, each weaver took part in three trials of Upper limb regions No. (%)
30 min. In each trial a certain tool is assessed, in which the
Shoulders 590 (68.4)
weaver performed weaving tasks using both traditional Arms 351 (40.7)
tool and the prototype with the same sharpness. Upon Elbows 241 (28)
completion of the trial, the checklist was presented to the Forearms 220 (25.5)
weaver and her/his perception was measured. Based on the Wrists 375 (43.5)
Hands 153 (17.8)
results, the ergonomic score for each tool was, then,
Fingers 271 (31.4)
calculated.
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Table 3
Hand anthropometric dimensions of Iranian carpet weavers (in mm)
Percentiles SD Percentiles SD
Fig. 3. Weaving knife; Top: knife with new ergonomic handle, Bottom:
traditional design.
Fig. 4. Weaver’s hand posture during work with weaving knife prototype.
Fig. 6. Weaver’s hand posture during work with the weaving scissors
prototype.
a desired handle diameter for the scissors, three proto- traditional hand tools greatly need redesigning. Any
types with handle diameters of 10, 15 and 20 mm were improvement in the design of carpet weaving hand
made and tested. As the weaving scissors were applied in tools may considerably improve health and safety of a
precision tasks, in accordance to NIOSH recommendation large number of weavers working in Iranian carpet
(2004), 80 mm was considered for open grip span of the industry.
scissors. This study focused on redesigning three dominant types
Prototype testing results: In 80% of cases (eight weavers), of common hand tools in carpet weaving operation,
the scores of usability tests were above 90 for all three including weaving comb, knife and scissors. The results
prototypes. According to the interpretation of of the usability test indicated that the ergonomic handles
checklist score proposed by Dababneh et al. (2004), this were comfortable and applicable to the weavers. No
meant that the prototypes were not lacking any soreness was reported in the palm of hands by the
highly important ergonomic design features. In 20% of participants while working with the new tools. During
cases (two weavers), the scores ranged from 77 to 85 for the work with the prototypes, the wrist was in appropriate
three prototypes. All scores obtained for the old hand tools posture. Generally, the results of the usability test showed
were lower than 70. The Wilcoxon signed-rank test that the new designs were applicable and acceptable for the
revealed significant differences between the scores of the weavers.
old and the new designed tools. Based on the results of
statistical analyses, there was a significant preference
towards the comfort and applicability of the prototypes
(po0.01). 5. Conclusion
During the prototype testing, based on the participants’
suggestions, some modifications were undertaken in the This study showed that upper limbs MSDs occurred
prototypes as follows: at a high rate among carpet weavers. From the usability
test, it could be concluded that, new hand tools caused
The shape of comb handle was changed from round to the concentration of contact stress on the palm of hand
oval with 35 and 25 mm of diameter. to be eliminated. The designed handles were perceived
The shape of knife handle was changed from round to more comfortable than conventional ones. The new
oval with 15 and 20 mm of diameter. The handle length ergonomically designed weaving hand tools were
was acceptable for the weavers. found to be applicable and acceptable for the carpet
The scissors with 15 mm of handle diameter were weavers. However, further study is needed to make
preferred by the weavers. The designed handle appropriate revisions to the ergonomically designed
length and span were found to be acceptable for the tools based on quantitative measures of musculoskeletal
weavers. loading.
In this study, no attempt was made to measure the
4. Discussion effects of the new weaving hand tools on weavers’
performance. Further field trials will be needed to test
The questionnaire showed that symptoms from efficiency under real production conditions.
the upper limbs were common among weavers. High
percent of weavers had experienced some kind of
symptoms from the upper limbs during the last 12 months Acknowledgement
(Table 2). This is in agreement with the results of
the findings of the study of Choobineh et al. The authors gratefully acknowledge the support of
(2004a). According to literature, these problems can be Center for Carpet Research, Iranian Ministry of Com-
attributable to hand tools design issues (Lewis and merce.
Narayan, 1993; Kadefors et al., 1993; Armstrong et al.,
1982; Aghazadeh and Mital, 1987; Armstrong, 1986;
Sperling et al., 1993).
Similar to other hand tools, the purpose of the handle Appendix A
usage in carpet weaving tools is to facilitate the transmis-
sion of force from the weaver’s musculoskeletal system to Checklist used for ergonomic evaluation of carpet
the tool or the carpet she/he is weaving. To optimize force weaving hand tools, including weaving knife, weaving
transmission, it is necessary to optimize handle design comb and weaving scissors, modified from Dababneh et al.
(Pheasant, 1999). Therefore, in this study the handle design (2004)
was considered the critical factor in safe, comfortable and Please respond to each item on the checklist by ‘‘Yes’’,
easy use of the carpet weaving hand tools. ‘‘No’’ or ‘‘NA’’ (not applicable). Write the score in the
Poor designed, traditional hand tools are commonly ‘‘Score’’ column. Add the scores of all items to get the total
used in carpet weaving operation. It seems that these score of the usability test.
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M. Motamedzade et al. / International Journal of Industrial Ergonomics 37 (2007) 581–587 587
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