c


 
  
   
@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
’Learning Curves of Several Months to
Attain Needed Skill Levels for Many
Jobs
’Difficulty in Applying Modern
Automation Technologies to Fabrics
Processing
 c


@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)
  

    
@ 0% 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
  

    
@ 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
 
 

@ 
and  
are Stressful to All
Upper Limbs
@   

are Associated With Pain in the
Shoulders, Wrists, and Hands
@  
is Associated With Elbow Pain
@ º  are Associated With
CTDs of the Hands and Wrists
@ Foot Operated Sewing is Associated With Pain
in the Back
     

@ Analysis RevealsThat 40% of Operators

at Sewing Machines Stoop Forward > 20o
Throughout the Machine Cycle
@ 60% Tilt Their Heads Forward > 20o
Throughout the Machine Cycle - Why?
’Visual Demands of the Work
’Geometry of the Work Station
’Inadequate Seating
     



@ 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
  

@ 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
 
  

@ 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
  !
" 
@ As Many as 100% of Piecework Operators in


# 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
   $c  
@ 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
  %  
&
 %
c
 

@ 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)
    '

  '
%% 

#

@ 30´ Fixed TableTop Height
@ Point of Operation Between 4-´ Above
TableTop
@ Sewing Machine Tilted 11o Toward Operator
@ For Jobs of Longer Duration Sewing - Bench
Mounted Arm Rests
@ Adjustable Chair
@ Adjustable Foot Rest With Movable Machine
Control
  c
 
@ 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
   #  

@ Eliminates Heavy Lifting by Operators or
³Bundle 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
   #  

@ 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
 # #$  

@ Conventional Textile/Apparel Industries Use
the  
&( - 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
 # #$  

@ 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
 # #$  

@ 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
  ' 
@ American Textile Manufacturers Institute
(ATMI) Washington DC
@ ATMI † $ ( $ 

Program
@ Must Have Comprehensive Program to Join
@ Must be Willing to Interact With Other
Members Companies
@ Nearly Half of ATMI Member Companies
Participate
  ' 

@ National Institute for

Occupational
Safety and Health (NIOSH)
@ 800-35-NIOSH
@ NIOSH Publication: c $
c
 
, January 199

 
&&
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