Importance and need of ergonomics in the apparel industry

by K.Saravanan, Senior Lecturer, Department of Textile Technology,

Kumaraguru College of Technology, Coimbatore.

Abstract: Today most of us spend our working days carrying out repetitive activities in awkward postures. At first we will not be
aware of this because it feels comfortable. If we do not sit properly, take regular breaks and also use correctly positioned furniture
and equipment, we become vulnerable to pain and discomfort. Injuries and muscle pain affecting the wrists, shoulders, neck and
back are common problems for workers in the garment industry. These conditions are usually related to overuse and can become
unbearable, if left untreated. Even stress, which causes muscles to tense, can be a contributing factor as can adverse working envi-
ronments, such as those are too hot or too cold, inadequate illumination, poor air quality and noise level, need attention.

Introduction how it affects us.

Ergonomics is a science
Features in
that focuses on designing
garment industry Work surface height should
be around elbow level
Work surface
thickness 5 cm
maximum a job for the worker.
that could be
Ergonomically-designed
improved to pre-
Thigh clearance job would ensure that a
vent injuries 20 cm maximum
min taller worker had enough
include; commu- 40 cm

Seat height space to safely perform

nication, involve- 34-45 cm
(adjustable to each
his or her job, and also
ment of worker)

that a shorter worker

employees in
could reach all of his or
decision making,
her tools and products without reaching beyond a comfortable
education and training of employees and management on pre-
and safe range. The opposite of this, and what typically happens
vention strategies, and the ergonomic conditions at the plant.
in the workplace, is that a worker is forced to work within the
The clothing industry is generally seen as a safe place to work,

Apparel & Knitwear

and when compared to other industries, there are relatively few
serious accidents in clothing plants. The hazards we face are dif-
ferent. The major health risks in this industry do not arise from
immediate, potentially fatal hazards. Instead, the risks that cloth-
ing workers face come from more subtle hazards whose effect
accumulates over time.
Sewing machine operators face a substantially higher risk of
muscle pain and injury than workers in other jobs. Studies also
show that frequency of persistent neck and shoulder injuries
increases with years of employment. 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.
The physical characteristics
of the job are an important risk
factor for muscle pain and
injury. The risks for sewing
machine operators have been
linked to conditions such as
poor workstation design and
chairs, and organizational fac-
tors such as the piecework
system.
Factors such as repetition,
force, posture and vibration
are associated with higher rates of injury. But you cant look at the
workstation alone to understand these injuries. There is growing
evidence that other factors are linked to injuries, some of these
factors include high work pace, lack of control over the job,
excessive workload, lack of co-worker support and general work
environment. The factors that relate to reduced injury rates
include empowerment of the workforce, safety protocols, greater
seniority of the workforce, good housekeeping and active role of
top management.
The Meaning of 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
confines of the job or workstation that is already existed. This
may require employees to work in awkward postures, perform
the same motion over and over again or lift heavy loads all of
which could cause work-related musculoskeletal disorders.
These injuries often start as minor aches and pains but can
develop into disabling injuries that affect our activities of daily
living such as laundry, hobbies (playing field games, trucking,
etc.) and even the ability to pick up our children. Ergonomics aims
at preventing injuries by controlling the risk factors such as force,
repetition, posture and vibration that can cause injuries to
develop.
Injuries and illnesses among textile and apparel workers

70% of sewing machine operators using foot controls report
back pain,

35% report persistent lower back pain.

25% have suffered a compensable cumulative trauma disor-
der (CTD).

81% reported CTDs to the wrist.

14% reported CTDs to the elbow.

5% reported CTDs to the shoulder.

49% of workers experience neck pains.

Absenteeism increases as working conditions worsens.

Loss of worker force due to injuries or high turnover is asso-
ciated with working conditions.

Hand sewing and trimming are stressful to 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.
Some fundamental ergonomic principals that should be fol-
lowed in our workplaces are:
(a) Proper tools
Tools should be appropriate for the specific tasks being per-
formed. Your tools should allow you to keep your hands and
wrists straight the position they would be in if they were hang-

PTJ January 2011 57

 ing relaxed at your side. The
workers should bend the tool
not the wrist.
The tool should fit comfort-
ably into your hand. If the grip
size is too large or too small, it
will be uncomfortable and will
increase the risk of injury. Tools
should not have sharp edges,
create contact stresses in your
hand, or vibrate.
(b) Keep repetitive motions to a minimum
Workstations or tasks can often be redesigned to reduce the
number of repetitive motions that must be performed. Using a
power-driven screwdriver or tools with a ratchet device can
reduce the number of twisting motions with the arm. To prevent
ergonomic injuries workers should be encouraged to rotate tasks
or take frequent, short breaks to stretch and relax muscles. Work
stations should allow enough space for the tasks have appropriate
working height, and provide proper seating. Manufacturing tools
and machinery should incorporate ergonomic design principles
and should not require an excessive amount of force to operate.
Some tasks can be automated or redesigned to eliminate repeti-
tive movements and musculoskeletal injuries.
(c) Avoid awkward postures
Apparel & Knitwear
Your job should not require you to work with your hands
above shoulder height on a regular basis. Arms should be kept
low and close to your body. Bending and twisting of your wrists,
back and neck should also be avoided.
(d) Use safe lifting procedures
Avoid lifting objects that are too heavy. Use more than one
person or a mechanical device to reduce the load. Your worksta-
tion should not require you to lift objects above your head or
twist your back while lifting. Keep the load close to your body
and ensure that you have a good grip. Heavy and frequently
lifted objects should be stored between knee and shoulder height
not on the ground or above your head.
(e) Get proper rest
The workers need to rest their body and mind in order to pre-
vent injuries. Give your muscles a rest during your coffee breaks,
58 PTJ January 2011
lunches and weekends by doing something different from what
you do in your job.
For example, if you stand all day, while performing your job
you should sit down to rest your legs and feet during your breaks.
If you sit down, when working you should stand up and walk
around during your breaks to give your back a rest and to
increase circulation in your legs. By doing this the musculoskeletal
injuries can be prevented.
(f) Other things to consider
Chemicals also play a part in garment manufacturing. Dyes,
enzymes, solvents and other chemicals are used to create differ-
ent fabric finishes and durability. So, proper ventilation, respira-
tory protection, and other personal protective equipment are
important to protect workers during chemical processing. The
same safety steps should be taken for workers, who handle the
finished material and may be exposed to excess chemicals and
off-gassing.
Because much of garment work involves close viewing of the
garment, eye protection is critical. Garment workers can avoid
eye injuries by using proper shields on high-speed sewing
machinery or safety glasses where appropriate. Also, adequate
task lighting at individual workstations can prevent eyestrain.
Some garment manufacturing equipment can be very loud, so
proper hearing protection may be necessary. Because a garment
factory uses many heated processes, it is important for workers to
avoid heat stress by labeling and guarding hot surfaces and drink-
ing plenty of water during their shift. Proper ventilation can help
to reduce ambient temperatures and ensure worker comfort.
Conclusion
The garment industry should focus and develop a good work-
ing conditions to reduce the injuries created to their workers since
there is ample room for ergonomic improvements in the clothing
industry. With proper training and instruction, machine guarding,
personal protective equipment and ergonomically designed work
systems, garment workers can manufacture products in safe and
healthy workplaces.
The garment industry needs to continuously identify the
problems and, more importantly, implement solutions to reduce
the risk of injuries in situations where they know problems exist.
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