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Applied Ergonomics 35 (2004) 493496

Technical note

Ergonomic intervention in carpet mending operation

Alireza Choobineha,*, Reza Tosianb, Zahra Alhamdic, Mohammadhassan Davarzanieb
a

Department of Occupational Health, School of Health, Shiraz University of Medical Sciences, PO Box 71645 111, Shiraz, Iran b Industrial Design Department, School of Art and Architecture, Azad University, Tehran, Iran c Cultural Heritage Organization, Fars Main Ofce, Shiraz, Iran Received 16 April 2002; accepted 26 January 2004

Abstract Carpet mending operations are performed in traditional workshops in a squatting position. Seventy-two menders were questioned regarding musculoskeletal disorders (MSDs). Among the menders, knees, back and shoulders problems were more prevalent compared to other body regions. Based on the problems found, a new workstation was developed and eight menders were asked to work in the new workstation. They were observed and evaluated with the RULA technique and their opinion on the improvement was asked working on four frequently seen tasks. The new workstation improved working posture noticeably. In 57% of the cases, the new workstation was evaluated good or very good and the comfort was increased. r 2004 Elsevier Ltd. All rights reserved.
Keywords: Carpet mending; Working posture; Design

1. Introduction Carpet mending is an important operation in the carpet industry. Carpets are always likely to get damaged due to different reasons. Carpet mending deals with repairing of carpet damaged parts such that it is not easily recognizable. In Iran, the art of mending has a direct effect on the carpet economy. Carpet menders, in general, revitalize dead capital and, in their own way, earn considerable hard currency for the country (HajiNasiry, 1998). Carpet mending as an informal small-scale industry is performed in traditional workshops in which one to at most 15 workers do the mending operations with simple, old-fashioned hand tools. In general, there are no proper facilities for heating, cooling and lighting in mending workshops. In some cases, carpets are repaired in open space, causing exposure to harsh outdoor conditions. Mending operations are performed in a squatting position in which menders fold their knees under their bodies while sitting on the oor (Fig. 1). In this condition, the back is bent excessively and postures
*Corresponding author. Tel.: +98-917-118-4450; fax: +98-711-7260225. E-mail address: alrchoobin@sums.ac.ir (A. Choobineh). 0003-6870/$ - see front matter r 2004 Elsevier Ltd. All rights reserved. doi:10.1016/j.apergo.2004.01.008

of different parts of body dramatically deviate from the neutral. Many experienced menders leave their jobs because of poor working conditions and musculoskeletal problems and start new business. By this means, their valuable, artistic experiences are lost. The present study had the following goals: 1. Determining the prevalence of musculoskeletal problems in menders population; 2. Improving the working conditions and assessing the working conditions improvement.

2. Materials and methods The present study consisted of two phases. Phase 1: A cross-sectional population-based study was designed to evaluate body postures and musculoskeletal problems among menders. In all, 12 workshops with 72 male menders participated in this study. All workshops were visited and all menders were interviewed. Required data on personal details and musculoskeletal problems was collected, using a questionnaire and general Nordic Questionnaire (Kuorinka et al., 1987).

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494 A. Choobineh et al. / Applied Ergonomics 35 (2004) 493496 Table 1 Specications of the designed mending table Seat height adjustable range Seat forward slope Table height (the front edge) Table surface area Table surface angle adjustable range (in relation to horizontal line) 5570 cm 10 85 cm 70 cm 210 cm 070

Table 2 Personal details of the carpet menders population studied (n=72) Age (year) Fig. 1. A typical working posture adapted in order to perform mending operation. Work experience (year) SD 11.5 Range 130 Weekly working hours Mean 49.6 SD 14.7

Mean SD Range Mean 29 10.5 1755 10.6

Job analysis indicated that mending operations consisted of 14 tasks. Making carpet binding, wrapping, double knots and splitting and weaving were considered the most common tasks and were selected for further assessment. In these tasks, working postures were assessed by the RULA technique (McAtamney and Corlett, 1993). According to this method a score is calculated for the posture of each body part. Score 1 indicates the most neutral posture and score 4 shows the worst position. The combined individual scores for shoulder, elbow and wrist give score A and those for neck, trunk and legs give score B. Muscle use and force exerted in each mending task are attributed a score of 1 and 0, respectively, because they are static posture or highly repetitive without considerable loading. These scores are added to scores A and B to obtain scores C and D, respectively. Combination of scores C and D, called grand score (ranging from 1 to 7), shows the musculoskeletal loading associated with the menders posture. Low grand scores (1 or 2) indicate acceptable working posture (action level 1). For grand scores of 3 or 4, further investigation is needed and changes may be required (action level 2). Prompt investigation and changes are required soon for scores of 5 or 6 (action level 3). Finally, immediate investigation and changes are required for grand score of 7 (action level 4). Phase 2: In order to improve working conditions, a working table was designed and constructed. To determine design specications of the new workstation, anthropometric data of menders were collected. In this part, 30 menders out of the 72 participants were randomly selected and the required body dimensions were measured. Table 1 presents the designed mending table specications. Since carpets are usually heavy, the table was made of metal with an attached seat. Sitting on the attached seat increases the stability of the table. The seat

can be moved forward and backward in a rail within 45 cm range for adjusting the horizontal distance between the seat and the working surface. It is also possible to change the seat position along the table width (left and right directions) to make the mender able to change his position for easy access to all points of the table surface. As carpet mending is an active operation in which workers occasionally have to exert force, take different tools and move around, an active seat with a high sitting surface and 10 forward slope was used. An experimental test was conducted to assess applicability of the mending table and working posture improvement. Eight experienced menders (all male, mean age 28.4 years [SD=8.6], mean weight 68 kg [SD=8.5], mean stature 168.3 cm [SD=4.9], mean working experience 7 years [SD=6.1]) participated in this stage. Each mender took part in four trials of 30 min. They performed one of the four tasks of mending operations in each trial. Working posture of menders was assessed by the RULA technique and the results were compared with the traditional condition (sitting on the ground). Upon completion of each trial, menders perception about the new working condition was investigated.

3. Results Phase 1: Table 2 shows some personal details of carpet menders that participated in the study. The daily working hours of menders were long; 60% of menders worked more than 8 h/day. The prevalence of musculoskeletal complains during the last 12 months among the 72 menders studied is presented in Fig. 2. As Fig. 2 shows, the most commonly affected parts are knees, lower back, upper back and shoulders.

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A. Choobineh et al. / Applied Ergonomics 35 (2004) 493496
23.6% 19.4% 12.5% 9.8% 5.6% 9.8% 20.8% 20.8%

495

25% 20% 15% 12.5% 10% 5% 0%

Neck

50% 40% 30% 20%

43% 36%

14% 7% 0%

Elbows Shoulders

Upper back Wrists/Hands Lower back

Thighs Knees

Ankles/Feet

10% 0%

Fig. 2. The prevalence of musculoskeletal complains among menders during the last 12 months (n=72).

much worse

a little worse

equal

a little better

much better

Fig. 4. General judgment of the menders about working on the table in comparison to the traditional working conditions (n=8). Table 3 Working posture evaluation by the RULA technique in different tasks of mending operation while working on the table and in the traditional conditions Tasks Working condition Traditional Grand score Making carpet binding Wrapping Double knot and splitting Weaving 6 5 6 5 Action level 3 3 3 3 On the mending table Grand score 4 4 4 4 Action level 2 2 2 2

In all, 4278% of the menders perceived the postures in the new working conditions good and very good and 75% expressed their comfort during work. Fig. 4 shows the general judgment of the menders about the new workstation in comparison to the traditional working condition. 57% of the menders found working on the table better than working in the traditional conditions.

4. Discussion In carpet mending, awkward postures in different parts of body (i.e. bent neck and back, folded knees) were very common. The Nordic survey revealed that, among the menders, symptoms from knees, back and shoulders over the last 12 months were signicantly more prevalent compared to other body regions (p-value of test of proportiono0.01). This indicates that any interventional program for working conditions improvement should focus on eliminating awkward posture of the mentioned body regions. RULA survey indicated that after the intervention there was evidence of improvement in the scores. Working on the table caused body postures less deviated from neutral such that action levels were reduced from 3 in the traditional working conditions to 2 in the new working conditions. Working on the table improved neck, trunk and legs postures, but it caused the postures of upper and lower arms to get worse. Further investigation should be concentrated on improvement of upper limb posture. Reducing table height, as some menders suggested, may improve upper limb posture, but then to maintain optimal visual distance the inclination of neck and trunk may be increased and, therefore, should be taken into account. Most of the menders participated in the second phase of the study found their working postures in the new condition good and reported comfort. They believed that the new working conditions were better than the traditional conditions (Fig. 4). It indicates that the menders feel that the ergonomic intervention has improved their working postures.

In the traditional working conditions in different tasks, A, B, C and D scores ranged between 23, 56, 34 and 67, respectively. In the new working conditions in different tasks, A, B, C and D scores ranged between 24, 23, 35 and 34, respectively.

Fig. 3. Carpet mending operation performed on the designed table. Neck, trunk and legs postures are acceptable and nearly neutral. (Arrows show the adjustability of the seat position).

Phase 2: In all tasks, grand scores of the traditional working conditions were higher than those of working on the mending table and consequently action levels were higher (see Table 3 and Fig. 3).

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5. Conclusion The working conditions of carpet menders especially the working postures need improvement. In this study, the working posture was improved by developing a new working table.

References
Haji-Nasiry, M., 1998. Carpet restoration, an unknown art (part I). Iran Rugs No. 4, 67. Kuorinka, I., Jonsson, B., Kilbom, A., Vinterberg, H., BieringSorensen, F., Andersson, G., Jorgenensen, K., 1987. Standard Nordic Questionnaires for the analysis of musculoskeletal symptoms. Appl. Ergon. 18 (3), 233237. McAtamney, L., Corlett, E.N., 1993. RULA: a survey method for the investigation of work-related upper limb disorders. Appl. Ergon. 24 (2), 9199.

Acknowledgements The authors wish to thank Dr. M.A. Lahmi and Professor H. Shahnavaz for their advice.