PARAMETERS FOR ERGONOMICALLY DESIGNED SEWING MACHINE WORK STATION USING WORKERS PERCEPTIONS

BALRAJ SINGH, CHANDANDEEP SINGH, KULDEEP SAREEN Department of Mechanical and Production Engineering Guru Nanak Dev Engineering College, Gill Park Ludhiana, Punjab-141006, India Email: cdsg@rediffmail.com ABSTRACT Ergonomic field is a vast field. In our daily life, ergonomics is used everywhere i.e. in cars, in bikes, in an aeroplanes, in computer workstation design etc. These ergonomically fit and designed things make the lifestyle better. Growing environment of fashion, styles of clothing etc, demands greater expectation from the sewing machine operator. Several studies are shown that there is a need of ergonomically fit sewing machine workstation so that sewing machine operators can perform their fiddy tasks comfortably. The objectives of this paper are to find out workers perceptions about the problems occurred during sewing work and to find out those human body parts which require more attention for ergonomic design. The present study was initiated where Workers perceptions were measured by preparing questionnaire to find out difficulties during sewing work. Questionnaires were filled up by 100 sewing machine operators from different parts of the region. The questionnaire includes the different modules; 1) Perceived posture 2) Localized postural discomfort 3) Estimated endurance time. Workers perceptions were analyzed by finding their critical values. Criticality index of questionnaire was calculated for concluding the most critical areas. The results were concluded with the help of criticality index. It has been found from the obtained results of questionnaire modules, the major critical areas are posture of neck, posture of left lower leg, posture of right lower leg, discomfort of whole body. In relation to these critical areas, the recommended parameters of treadle sewing machine workstation are desk slope, pedal position and desk height. KEYWORDS: Ergonomic design, endurance time, Localized postural discomfort, perceived posture, ,
sewing machine workstation, workers perceptions

1. INTRODUCTION In our daily life, ergonomics is used everywhere i.e. in cars, in bikes, in computer workstation design etc. These ergonomically fit and designed things make the lifestyle better. With the increasing awareness of ergonomics, the emphasis shifted from the generally accepted policy of fitting man to his machine by means of selection and training to fitting the machine to the majority of men who work with them. The modern approach, however, is of

compromising nature: machine together.

fit

man

and

Growing environment of fashion, styles of clothing etc, demands greater expectation from the sewing machine operator. In return for the operator to work efficiently, the Sewing Machine operator must have an ergonomically fit workstation. The efforts were made to make the sewing machine workstation ergonomically fit to create or provide a healthy and comfortable working environment. The introduction of sewing machine in the workplace has led to

numerous reports of health disorders from its use. Workers involved in sewing activities, such as manufacturing garments, shoes and airplane or car upholstery, may be at risk of developing musculoskeletal disorders. Musculoskeletal disorders may be characterized by pain, number ness and a lack of mobility in the affected area, usually the hands, shoulders and backs. Sewing related injuries have been documented in the areas of sewing station, performing fine work or scissor work and material handling, among others. Employees encounter several risk factors at sewing workstations, such as awkward arm, neck and leg postures. These are influenced by the size of the worker and the design of the workstation. Workers often maintain awkward shoulder, elbow and wrist postures while sewing because of improper chair height or position. A typical workstation includes work surfaces, space for all activities and components of the task, seating for operator; desk for sewing operation; pedal for operating foot. Several studies have shown that operator of Sewing machines report discomfort in the left shoulder, the neck, the back, and the lower extremities (e.g. Vihma et al., 1982; Wick and drury, 1986; Blader et al., 1991). These complaints may be caused or aggravated by the seated working posture which is characterized by an elevated left upper arm posture, a forward inclined posture of the head and trunk, and non optimum (i.e. relatively unfavourable) ankle and knee angles, respectively. Vihma et.al., (1982) reported that sewing machine operators work was more static. Musculoskeletal complaints occurred more frequently among sewing machine operators especially in neck, shoulders and lower limbs. Wright, Susan., (2001) found that a welldesigned, convenient sewing area large or small saves time and energy. It does not have to be a whole room dedicated just to sewing. It can be seldom-used

closet, an out-of-the-way corner or a cabinet especially designed for sewing. Theresa Chan, L.K., (2002) developed an ergo-work seat with ergonomic considerations for sewing operators. Poor ergonomic design of sewing machine systems can lead to many health problems for all users, although users with disabilities can encounter additional problems. Keeping this into mind, the present study was initiated where Workers perceptions were measured by preparing questionnaire to find out difficulties during sewing work. This paper demonstrates the important determinants of working postures and its criticality. This is based on the workers perceptions regarding the different postures of the body while doing the work. There are following objectives of the study: a) To find out workers perceptions about the problems occurred during sewing work. b) To find out those human body parts where the study is to be concentrated. c) To co-relate the problems with the recommended parameters of the Sewing machine. 2. METHODOLOGY this study is purely based on the workers perceptions. A survey instrument was developed to examine work postures during sewing machine working. A questionnaire was prepared and was filled by the different tailors from the different parts of the country (north India). Questionnaire was structured based i.e. there were definite, concrete and predetermined questions. These questionnaires were filled up by sewing operators directly by approaching to them. The sample of 100 tailors on random basis from villages, towns, and cities of north India are taken for filling the questionnaires. The Likert scale was used to analyze the questions for further conclusions and results. Scaling

describes the procedures of assigning numbers to various degrees of opinion, attitude and other concepts. Workers perceptions were recorded by a questionnaire, containing different questionnaire modules. These modules are Perceived Postures, Localized postural discomfort and estimated endurance limit. Criticality Index was calculated in each of the module of the questionnaire to find out critical postures. Based on the critical postures, the workstation characteristics were recommended to make sewing machine workstation ergonomically fit. The general profile of the respondents is as follows: a) Age: The minimum age of the workers was 30 years and maximum age was 67 years. The average age was 44 years. b) Height: The range of height of the workers is 162cm-172cm. The average height of the worker is 165 cm. c) Weight: The average weight of the workers is 74 kg. The following three modules are discussed to identify the critical parameters: 2.1 Perceived posture The operator was asked to rate his perception of the posture of the neck, back, left shoulder, right shoulder, left upper arm, right upper arm, left lower leg, right lower leg, left foot, and right foot. This written response was based on seven-point scale (1= very favorable, 3=favorable, 5=unfavorable, 7= very unfavorable. Scores of 2,4 & 6 were available for intermediate responses). The operators were asked to rate as per the Favorable or unfavorable condition of the different postures of the human body.

2.2 Localized Postural Discomfort The operator was asked to rate his posture discomfort in different parts of body using a scale ranging from 0(no discomfort) to 5 (very severe discomfort). 2.3 Estimated Endurance Time The operator was asked to estimate how long he could operate at the experimental workstation adjustment without difficulty during a regular working day. Operator was asked to rate on a five- point scale (1= more than 8hours, 2=6-8hours, 3=46hours, 4=2-4hours, 5= less than 2hours). 3. RESULTS AND DISCUSSION The data on the working postures and their perceptions were collected and analyzed for further recommendations. The results for different modules are discussed below: 3.1 Perceived posture The response of 100 tailors for different postures of the body parts are given in table 1. The observations are written for each category and criticality index was calculated. Criticality Index for all these observations were calculated to find out the important and significant postures. These most critical postures are recommending the parameters of sewing machine workstation. Criticality Index was calculated by using the given formula :
Criticalit y index =

XY X
i

i i

Where Yi = perceptions of the workers in specific category Xi = Weightage given to each point on scale

Table 1 Response rate of workers for Perceived postures

Parameter* Posture Posture Posture of Posture of Posture of of neck of back left right left upper shoulder shoulder arm (A) (B) (C) (D) (E) Posture of right upper arm (F) Posture of left lower leg (G) Posture of Posture Posture right of left of right lower leg foot foot (H) (I) (J)

1 2 3 4 5 6 7 Criticality index

32 06 54 02 05 00 01 8.78

23 08 46 05 16 01 01 10.35

47 05 46 02 00 00 00 7.25

46 05 47 02 00 00 00 7.32

49 06 43 02 00 00 00 7.07

49 06 43 02 00 00 00 7.07

40 06 41 04 09 00 00 8.42

40 06 41 05 08 00 00 8.39

50 02 39 02 05 02 00 7.71

50 02 39 03 05 01 00 7.64

* 1= very favourable, 2= intermediate response b/w 1 and 3, 3= favourable, 4= intermediate response b/w 3 and 5, 5= unfavourable, 6= intermediate response b/w 5 and 7, 7= very unfavourable.

As shown in Table 1 and Figure 1, the critical postures are Postures of back (Criticality index= 10.35), posture of neck (Criticality index= 8.78), posture of left lower leg (Criticality index= 8.42), posture of right lower leg (Criticality index= 8.39). Hence there is a need to ergonomically design a sewing machine workstation by considering above postures. 3.2 Localized postural discomfort The operator was asked to rate his postural discomfort in the different parts of a human body using a scale ranging from 0 (no discomfort) to 5 (very severe discomfort).After getting the response,

criticality index for all these discomfort regions were calculated. Criticality index versus discomfort in different body parts of sewing machine operators is shown in figure 2. It has been found that most critical parts which are having high degree of discomfort are discomfort of back (Criticality index= 5.46), discomfort of whole body (Criticality index= 4.13), discomfort of left leg (Criticality index= 1.93), discomfort of right leg (Criticality index= 1.73), discomfort of upper neck/back (1.66). There is a need to give attention on these discomfort body parts.

Table 2. Shows the perception of operators about localized postural discomfort

No of operators rated their perception

PARAMETERS No discomfort Some discomfort Minor discomfort Major discomfort Severe discomfort Very severe discomfort
Criticality Index

A
91 07 01 01 00 00 0.8

B
94 03 01 02 00 00 0.73

C
58 25 14 03 00 00 4.13

D
86 07 03 04 00 00 1.66

E
90 05 03 02 00 00 1.13

F
99 00 01 00 00 00 0.13

G
97 02 01 00 00 00 0.26

H
81 13 03 02 01 00 1.93

I
81 14 03 02 00 00 1.73

J
40 42 15 02 01 00 5.46

# Description of parameters: : A= Discomfort of neck, B= Discomfort of neck/upper back,C= Discomfort of back, D= Discomfort of upper neck/back, E= Discomfort of neck/back F= Discomfort of left shoulder /neck, G= Discomfort of right shoulder/neck, H= Discomfort of left leg , I= Discomfort of right leg,J= Discomfort of whole body

6
12 10 8.78 Criticality Index 8 6 4 2
7.25 7.32 7.07 7.07 10.35 8.42 8.39 7.71 7.64

5.46 4.13

Criticality Index

4 3 2 1 0 0.8 0.73 1.66 1.13 0.13 0.26 A B C D E F G H I J 1.93 1.73

0 A B C D E F G H I J

Fig 1 shows the criticality index of the perceived postures

Figure 2 shows the criticality index of discomfortness

3.3 Estimated endurance time The operator was asked to estimate, on the basis of his perceptions, how long he could operate at the experimental workstation adjustment without difficulty during a regular, working day. The estimated endurance time is shown in figure 3. 42% workers said that they can do the work for 6-8 hours without any difficulty and there are only 5% workers who can work only less than 4 hours
Between 2-4 hours (5%) Between 4-6 hours(14%) More than 8 hours (39%)

3.4 Parameters for workstation design

sewing

machine

Between 6-8 hoursr (42%)

Fig 3. Endurance time of sewing machine operators

It has been found that the critical perceived postures are posture of back, posture of neck, posture of left lower leg, posture of right lower leg. In localized postural discomfort portion , the critical points are discomfort in whole body, discomfort of back, discomfort of left leg and discomfort of right leg. There is a need to design a sewing machine workstation to make it more comfortable. Parameters for sewing machine workstation are recommended by considering all above factors (shown in table 3).Figure 4 shows the different parameters that can be considered during sewing machine workstation design. The desk height as shown is above the elbow height which will compensate the variations because of height variations of the workers.

Table 3 recommended parameters corresponds to critical areas

S. No. 1 2 3 4. Critical areas Posture of back/neck Posture of left lower leg Posture of right lower leg Discomfort of whole body Recommended parameters Desk slope, Desk height Pedal position Pedal position Desk height, Desk slope, Pedal Position

Figure 4 shows the parameters for ergonomic design of sewing machine workstation

4. CONCLUSIONS It has been concluded that there is a need of ergonomically fit ewing machine workstation for the workers. The workers perceptions suggest critical areas which need more attention. The study shows the critical perceived postures are posture of back, posture of neck, posture of left lower leg and posture of right lower leg. In localized postural discomfort portion, the critical points are discomfort in whole body, discomfort of back, discomfort of left leg and discomfort of right leg. By considering these above factors, parameters for sewing machine workstation design are recommended. These determinants are Desk height, desk slope and pedal position. ACKNOWLEDEMENTS This study is a part of thesis work of M. Tech student. The authors wish to thank the Research and Development centre for Bicycle and Sewing Machine, Ludhiana who helped to inspire and complete the thesis work.

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