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% 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 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) 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 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 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 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 > 20 o Throughout the Machine Cycle 60% Tilt Their Heads Forward > 20 o Throughout the Machine Cycle - Why? Visual Demands of the Work Geometry of the Work Station Inadequate Seating Analysis Reveals That 40% of Operators at Sewing Machines Stoop Forward > 20 o Throughout the Machine Cycle 60% Tilt Their Heads Forward > 20 o 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 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 Improved Seating is Readily Available 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 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 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 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) 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 11 o Toward Operator For Jobs of Longer Duration Sewing - Bench Mounted Arm Rests Adjustable Chair Adjustable Foot Rest With Movable Machine Control 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 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 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 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 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 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 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 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 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) NIOSH NIOSH Publication: Elements of Ergonomics Programs, January 1997 National Institute for Occupational Safety and Health (NIOSH) 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