Introduction

Challenges Facing the Industry

Today:
Competition From Overseas

Companies
Shortage of Available 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 .

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% 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

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

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

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 for Supervisors 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 11o 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
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
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
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