This document discusses ergonomic workplace design for the apparel industry. It begins with an acknowledgement and introduction on ergonomics and how repetitive stress injuries are common for garment workers. It then discusses specific ergonomic issues for stitching operations, including reaching for materials, setting up materials, manipulating materials, and pushing materials through sewing machines. Common problems with sewing workstations like table height, leg room, and chairs are also examined. The document provides solutions like adjustable workstations, proper lighting, friction aids, and job rotation. It emphasizes the importance of chair design, treadle placement, arm supports, and tilt-adjustable tables. Finally, it discusses other considerations like knee switches, hand controls, stress reduction,

1. Ergonomics Assignment
Submitted To: Mr. Joseph Reggy
Mr. Abdul Salam Sait
Submitted By:
Amalesh Deka
Rajeev Sharan
Alok Lievens
Semester-VII
Dept. Of Fashion Technology
NIFT-Bengaluru

2. Acknowledgement
“I’m just an wanderer picking up pebbles on the beach, while the vast ocean of
knowledge lies before me, unexplored”- Albert Einstein.
There are people who being what they are, inspire you to do things you never
thought yourself capable of doing. Among them is our Faculty MrJoseph Reggy
and Mr. Abdul Salam Sait who guided us in our first tentative steps in the field
of Ergonomics and related issues regarding Apparel Industry.
We would like to mention the name of Ms. Rajni Jain, CC-DFT, NIFT-
Bangalore all other faculty members of NIFT-Bangalore who have guided us in
various ways in our course of study at NIFT.
We would also like to thank all our class mates and our friends, who despite of
their own work, helped us in many ways.
Amalesh Deka
Rajeev Sharan
Alok Lievens
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Ergonomical Workplace Design for Apparel Industry

3. Introduction
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
environments, such as those are too hot or too cold, inadequate illumination, poor air quality
and noise level, need attention.
Features in garment industry that could be improved to prevent injuries include;
communication, involvement of employees in decision making, education and training of
employees and management on prevention strategies, and the ergonomic conditions at the
plant.
The clothing industry is generally seen as a safe place to work, and when compared to other
industries, there are relatively few serious accidents in clothing plants. The hazards we face
are different. The major health risks in this industry do not arise from immediate, potentially
fatal hazards. Instead, the risks that clothing 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 longterm 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 factors such as the piecework system.
Factors such as repetition, force, posture and vibration are associated with higher rates of
injury. But you can’t 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.
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Ergonomical Workplace Design for Apparel Industry

4. Ergonomics and Garment Industry
Ergonomics is a topic that affects us all; yet few of us have a good understanding of what the
term actually means or realize how it affects us.
Ergonomics is a science that focuses on designing a job for the worker. Ergonomically-
designed job would ensure that a taller worker had enough space to safely perform his or her
job, and also that a shorter worker could reach all of his or her tools and products without
reaching beyond a comfortable and safe range.
The opposite of this, and what typically happens in the workplace, is that a worker is forced
to work within the 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
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5. STITCHING
Stitching involves taking cut material,
placing it on the sewing mount, then
running it through a sewing machine. This
operation may require pinch grips and
awkward arm, neck, and trunk postures.
Force may also be required to push fabric
through the machine. Some of the common
risks and possible solutions associated with
stitching are listed below.
1. Moving Material to/from
Workstation
2. Setting Up Material
3. Manipulating Material
4. Stitching Material
MOVING MATERIAL TO/FROM WORKSTATION
Potential Hazard:
Workers reach overhead (Figs. 1 & 2), to the side (Fig. 3), behind, or down into tubs
to pick up or place fabric. This action can cause stress on the arms, neck, shoulders,
and back.
Fig. 1 Fig. 2 Fig. 3
Reaching overhead to Reaching overhead to Reaching to the side to
pick up fabric can place fabric. place fabric.
cause stress on the
arms, neck, and
shoulders.
Workers bend/twist to pick up fabric (Fig. 4), which can hurt a worker's back and
shoulders.
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6. Possible Solutions:
 Minimize overhead reach by:
Fig. 4
Lowering the rack (Fig. 4); or Lowering the
Placing station on platform clothing rack
or using height-adjustable can minimize
portable clothing racks or overhead reach.
tables.
 Minimize reaches to the side or Fig. 5
behind associated with picking up Minimize reach
new product or placing completed
fabric by: by placing
material closer
placing fabric/bins closer to to the worker.
the worker (Fig. 5);
placing fabric/bins at table
height;
using height-adjustable
fabric containers;
adding an extension to work
table; or
using an automated or
conveyor system that
transports the fabric
directly to and from the
worker.
 Use swivel chairs (Fig. 6), which
allow workers to turn to get bundles Fig. 6
and pieces, rather than twisting to
Swivel chairs
reach to the side or behind.
Swiveling can also make it easier allow workers to
for workers to sit down and get up maintain good
from the workstation. back posture.
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7. SETTING UP MATERIAL
Potential Hazard:
When setting up material for stitching, workers may have to flex or bend their necks to view
the position of the fabric.
Possible Solutions:
 Use automatic feeding and set up, which
eliminates the operator using awkward
postures.
 Provide proper lighting:
 Use adjustable task lighting to
make it easier for the worker to see
product during set up (Fig. 7).
 Ensure bulbs are replaced Fig. 7
frequently so they are functional at Adjustable task lighting.
all times.
 Provide properly positioned
general overhead lighting.
MANIPULATING MATERIAL
Potential Hazard:
 While manipulating fabric, employees
repeatedly use a forceful pinch grip (Fig.
8) between the thumb and index finger.
Fig. 8
Pinch grip.
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8. Possible Solutions:
 Use friction-increasing aids (Fig. 9) on fingers
to reduce amount of force exerted in the pinch
grip.
 Analyze tasks to determine force requirement
and use job/task rotation through tasks not
requiring pinch grip.
Fig. 9
Friction-increasing
aid.
STITCHING MATERIAL
Potential Hazard:
 Employees push fabric through the sewing
machine, which may require extending arms,
bending at the waist, and applying
force (Fig. 10).
Fig. 10
Awkward posture
Possible Solutions: causing ergonomic
 Use height adjustable tables (Fig. 11),
which, when properly adjusted, may reduce
arm extension and bending at the waist.
 Allow the machine to pull the fabric through
rather than having the operator push the
fabric.
 Reduce the distance between the operator
and the machine
Fig. 11
Height-adjustable table
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9. COMMON PROBLEMS IN A SEWING WORKSTATION:
The dimensions of the sewing table that should be considered are the:
Height
Shape
Tilt
Leg Room
Chairs
Height.
Sewing tables are not easily adjustable.
For a operator with short height, it create elevated shoulder postures and non-neutral elbow
and wrist postures.
For a operator with long height , it cause the operator to lean forward and flex his or her neck.
Leg room.
Sewing machine operators have limited legroom because of drawers and/or trash chutes
attached to the underside of the table.
Table angle.
The tilt improves visibility of the task and helps to keep the neck in a more upright position
while having the table at an appropriate height for the upper extremity.
Chairs
The chair is a critical piece of equipment for sewing machine operators who work in a seated
position. It can have a very large impact on the comfort of the worker and can affect the risk
of muscle pain and injury.
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10. Sewing Workstation Design:
The following key areas should be modified to make the sewing m/c ergonomically designed:
Chair and posture
Treadle and leg room
Correct height of table
Arm support
Visibility and tilt-adjustable tables
Lighting and surroundings
Chair and posture
Swivel chairs for workstation is needed. These chairs are adjustable in height, seat tilt, and
backrest position and their backrest is padded. They facilitate the necessary work and support
the worker’s spine.
One must bear in mind the size of the worker when determining the height of the chair andthe
position of the treadle. The height of the chair and position of the treadle must permit the
worker to occupy the seat with a straight sitting posture.
The worker’s foot should be able to easily operate the treadle. The angle of the knee should
be slightly greater than 90 degrees and the thighs should be horizontal.
When sewing, one should not remain permanently in a certain position but rather bedynamic.
This means to change sitting positions occasionally from front to centre of the seat and to
lean back to relax.
Treadle and leg room
Many sewing tables have a moveable treadle fixed on a traverse. Using screws the treadle can
be mounted to the front or rear. Even with a medium sized worker, it may be necessary to
move the traverse to the far edge of the table in order to permit the worker to have a
comfortable leg position. Sufficient space under the table allows the worker to move their
feet to an optimal position and thereby avoid excessive bending of the upper body. Hence,
components such as the motor, operating devices or drawers should not be installed under the
table top because they project into the leg area.
The height of many sewing tables is adjustable by turning a screw. However, a table frame
with electronic infinite adjustment of the height is more comfortable. The height of the table
should allow the worker to sit in a comfortable upright position. If the table is too low,
workers will have to hunch forward, putting strain on the back, neck and shoulders. If the
table is too high, workers will have to raise their shoulders to get their arms high enough to
work. This posture puts strain on the neck, shoulder and arms. Therefore, the fitting of the
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11. table base and thus the working height of the table top should be fixed so that the worker can
sit in an upright position and can reach and see all work areas,especially the sewing needle.
If the height of the table is too low and not adjustable, an increase of height by simple means
is also possible
Arm support
During sewing, the upper arms should loosely hang at a forward angle plus, depending more
or less on the sewing task, the shoulders should be braced (without force).
The worker should be able to comfortably rest their forearms without pressure on a large
working area (with well-rounded table edges).
Newly developed, ergonomically designed sewing tables have adjustable arm supports where
you can rest your forearm. This may be particularly useful for long and uniform sewing tasks
and by high volume.
Visibility and tilt-adjustable tables
When viewing of the sewing area is restricted by the head of the sewing machine, it can cause
awkward and excessive stooping.New sewing tables can often be tilted to improve the
visibility of the work area.
To obtain a slight tilt to your existing table, we can install a wedge between the table top and
the base. We should take into account the viewing distance between the head and the needle
(for small pieces and fine work approx. 30 cm and with larger pieces about 30 cm to 50 cm)
in order to obtain the best possible sewing position. The head should be inclined forward at
amax. 25°.
Lighting and surroundings
When setting up the sewing machine, the direction of view should be parallel to the front of
the window and the ceiling light strips. The ambient lighting should provide sufficient
brightness in the work area (e. g. Ceiling lighting, 500 lux). Additional lighting or lighting on
the workplace should be arranged in order to avoid high contrasts (differences in brightness).
The task lights should have a “goose-neck” so the light can be directed to the work area.
Lampshades should have ventilation holes, but where necessary these can be covered so that
the light is not directed through these holes towards the operator.
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12. Chair
The operator’s chair must have comfortable padded seat, a back rest, adjustable height, seats
slightly sloping towards the front etc.
Other Considerations:
Knee Switches
Place the knee switch so that it rests very close to the leg, just above the knee, and is well
padded.
Hand Controls
Ensure controls are located in a convenient position without being in the way.
Controls should be activated with a light touch applied at multiple angles.
Repetitive strain Reduction:
Work should be organized such that operators get up from their workstation to pick up their
next work order.
Repetitive strain can be reduced when operators assemble large parts or full garments. This
decreases repetition and increases variability and skill. Set reasonable limits for bundle sizes.
Psychological Factors:
Work-related stress is not an illness but it can lead to increased problems with ill health. If it
is prolonged or particularly intense it can lead to physical effects (such as heart disease and
gastrointestinal disturbances leading to ulcers) and psychological effects (such as anxiety and
depression). Work-related stressors include:
• Lack of communication and consultation between management and workers
• A culture of blame when things go wrong and denial of potential problems
• Excessively long working hours;
• Boring or repetitive work
• Poor relationship with management and fellow workers
• Bullying or sexual harassment
There are a number of solutions that management can introduce to deal with these Stressors,
including:
Set up communication channels for workers to talk to management without prejudice
Provide regular training and up-gradation programs to operators.
Allocate tasks according to workers skills, training and experience.
Improve methods of doing work.
Introduce ways to relieve stress such as:
- Play light music on the floor
- Make cool drinking water available for workers.
Introduce motivation tools.
Train supervisors and managers in ways and tools for creating a healthy and
comfortable work environment
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13. Annexure
Importance and need of ergonomics in the apparel industry By K. Saravanan ,
Senior Lecturer, Department of Textile Technology, Kumaraguru College of
Technology, Coimbatore.
Ergonomic Handbook for the Clothing Industry , Published by the Union of
Needle trades, Industrial and Textile Employees, the Institute for Work & Health, and
the Occupational Health Clinics for Ontario Workers, Inc. Pg. 24-42
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