cutting room ergonomics

8/3/2019 Cutting Room Ergonomics

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ERGONOMICS

Cutting Room ErgonomicsDate : 10th oct. 2011Presented By -

Abhinay KumarSatyam SinghShrey VijRishab Tandon

Kuldeep Meena

NATIONAL INSTITUTE OF FASHION

TECHNOLOGY, GANDHINAGAR

Under Guidance Of -Mr. Manoj Tiwari


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CUTTING ROOM IN TERMS OFERGONOMICS

Unlike sewing room, the cutting room mostly consists ofequipments and workstations on which work is to be done only instanding position.

So, there must be equipments and workstations designedaccording to the anthropometric data of human body in standingpostures.

The postures are different from the sitting workstations here.

Basically in the standing position the points which are taken underconsideration are workers height, arm length, hand length, Handbreadth etc.

Consideration is taken care of :

Workplace design

Task design

Equipment design


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AVERAGE MEASUREMENTS OF

HUMAN BODY

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ADVANTAGES OF STANDING

WORKSTATION

Reach is greater in standing than in sitting.

Body weight can be used to exert forces.

Standing workers require less leg room than seated

workers.

Lumbar disc pressures are lower.

It can be maintained with little muscular activity andrequires no attention.

Trunk muscle power is twice as large in standing than insemi-standing or sitting.


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STANDARD WORKING POSTURE


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STANDING POSITIONS

IDEAL POSITIONNORMAL POSITION


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IDEAL BODY POSTURE

Maintain the S curve in your spine

Feet flat on the floor

Knees and hips at a 90 degree angle

Elbows at 90 degree angle do not lean on elbows

Shoulders relaxed and elbows close to body

Head and neck in the upright position

Hands and wrist in the neutral positionAvoid: Poor body mechanics, twisted torso, slouching,kneeling, squatting, neck rotation/side bending, bent wrists,and reaching overhead.


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A WORKERS REACH

Usual work area/reach : (80-100 + 25) cm

Occasional work area/reach : (80-100 + 50) cm


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CUTTING DEPARTMENT

The primary tasks in the cutting department are:

Loading the spreading machine

Spreading the fabric

Cutting the fabric

Stacking cut pieces


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LOADING THE SPREADING

MACHINE
http://loading%20the%20spreading%20machine.docx/http://loading%20the%20spreading%20machine.docx/http://loading%20the%20spreading%20machine.docx/http://loading%20the%20spreading%20machine.docx/


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SPREADING THE FABRIC
http://spreading%20the%20fabric.docx/http://spreading%20the%20fabric.docx/


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CUTTING THE FABRIC
http://cutting%20the%20fabric.docx/http://cutting%20the%20fabric.docx/


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STACKING THE CUT PIECES
http://stacking%20cut%20pieces.docx/http://stacking%20cut%20pieces.docx/


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EQUIPMENTS USED IN CUTTING ROOMAND THEIR ERGONOMICS FEATURES


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SPREADING TABLE

Table dimensions : length - 340(approx.)

Width72

Height34

AdjustableHeight

Air blower beneath

the table


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Ergonomic features of cutting table :

adjustable height

air blower beneath table for easy movement of layers

smooth edges

width according to normal human hand movements

Smooth edgesHeight according to

normal human height


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MANUAL SPREADING MACHINE

Rollers for

movement Points for width sizeadjustment


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Ergonomic features :

width size adjustable

adjustable height according to table and worker

manual edge control

rollers adjustment for easy movement between onetable to another table


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STRAIGHT KNIFE

Handle for bettergrip

Swivel base plate for movement

27 height easy to

handle


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Handle for movement

to other tables


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Weight : 34 lbs(15.4 kg) easily moveable by cuttingperson

Height : 27

For better grip and easy movement extended holderis present

For transportation purpose on the upper part gripper

is present

For steady and vibration free working base plate is ofmetal, 8long and 5broad

a security handle that automatically drops the

presser foot leg and stops the machine when thehandle is released

ergonomic handle that reduces wrist strain

a swivel baseplate that turns easily even in the

hardest materials


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END CUTTER

Long Handle for longer

reach

Control panel in workers

reach Track formovement

of end

cutter


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For easy movement there is a gripper to move theend cutter length wise

Small in size

Attached to table so that the movement is notdependable only on the cutting man i.e. weight ofend cutter is distributed between table and the

cutting man

A long rod is attached to the end cutter to move itwith the table length without the movement of theoperator

Easy to attach and detach with tables

Fitted on the tracks from easy to and fro movementacross the table

Control panels are in the reach of cutting man


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BAND KNIFE

Curve inserted for better

reach to the blade

Emergency

light

ADJUSTABLE

TABLE HEIGHT


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Air flotation tableAdjustable Table height according

human height


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Adjustable table height

Air flotation for easy movement of layers during use

Additional Safety Device to ensure the operatorssafety

The lighting device to reduce operators fatigue

Auto Catch Device, to catch the knife when the blade

is broken.

A curvy portion is provided to fit the cutting man foreasy reach to the blade


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BAND KNIFE WORKERS REACH

25cm80-100cm

50cm


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LABELLING GUN

Handle for grip

Extra plastic griper


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gripper is provided for fast use of the labelling gun

small in size

weight is less

extra plastic grip is also provided


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FUSING MACHINE

Automatic sensor

Control panel near

the operator


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continuous fusing is done so no need to move thecut pieces every time

automatic sensor in case of any emergency

35 height of the machine bed which is according tonormal human height

Control panel is near the operators position to avoidany emergency

Operator friendly side swing design

Operator is protected from heat radiation


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GENERAL ERGONOMIC CONCERNSDURING WORK

Static postures

constantly work with their arms above shoulder level

Awkward body postures

the height of the workstation

Repetition of movements

Standing in one position for long periods of time

No foot rest

Awkward wrist postures

Workers should try not to twist their upper body whenplacing objects besides them

Vibration caused by different equipments

PROBLEM SOLVING TECHNIQUES


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PROBLEM SOLVING TECHNIQUES

Avoid static postures

For standing work, the height of the workstation should allow

workers to function with elbows at 90 degrees

workers should try and sit for short periods of time while

working to give their leg and back muscles a rest

Change position after a period of time

There must be a raised foot rest provided for standing

workstations

majority of work should be done between knuckle height and

shoulder level

Workers should move their feet, instead of twisting at the waist,

in order to face the area where the object is going to be placed

Avoid repetition of movements

Assign job according to worker, not worker according to job


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NORMAL WORK FLOOR ARRANGEMENT

Anti-fatigue mats for those who must stand for extendedperiods of time

Footrest to allow the employee to put one foot up andchange positions often

Floor surface is free of obstacles and flat

Keep work at comfortable height to maintain erectposture

Footwear with good support


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Avoiding MSDs needs Work Smarter,Not Harder

Work in neutral postures

Reduce excessive force & repetition

Keep everything in easy reach and at proper heights

Minimize static unsupported postures and pressurepoints

Use proper lifting

techniques and lift aides

Ask for assistance with difficult tasks

Take micro-breaks (stand, stretch, change tasks)

Maintain a comfortable environment


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GAPS IDENTIFIED IN WORKENVIRONMENT AND

EQUIPMENTS


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AREAS GAPS IDENTIFIED SUPPORTIVE FINDINGS

Cutting table Work height too high Complaints of postural

discomfort and pain in

shoulders, neck and hands

Sorting table Work height too high Complaints of postural

discomfort and pain inshoulders, neck and hands

Inadequate lighting Low level of lighting Complaints of visual strain and

blurred vision

Excessive noise Noise level exceeds 90dB Workers complaints

Dust Increased level in cutting

section

Complaints of respiratory

problems

Hot and humid work place Heat Humidity 23 to 57% Heat

exposure

Workers complaints Identified

as risk factor by hazard

identification and risk

assessment

Blade guard of the cutting

machine

Defects in design of blade

guard, non use of blade guards

Fifty per cent of workers

reported accidental cuts

General safety measure Absence of general safety

measures

Observed gaps

Personal protective equipment Absence of personal protective

devices

Observation and reported

incidences

O O


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SUGGESTED ERGONOMICFEATURES IN CUTTING ROOM

Efficient spacing between the cutting tables, racks, bandknife machine, fusing machines for better movement ofman and material.

Cutting table heights are according to normal human

height

Dustbins are provided according to the height of thecutting table and band knife machine

Racks heights are according to the normal humans hand

reach

Fabric store is near the cutting room so less movementof man and material

The illumination level is kept to standard illumination

level i.e. 750 lx.


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Cont

Provision of local exhaust ventilation that uses suction,based on the principle of a vacuum cleaner, is to beencouraged in the cutting and stitching sections toremove dust from the air.

Workers are suggested to wear fine mesh cloth dust

protectors.

The handles should be made of flexible polyethylenematerials, which even after prolonged and regular usegive a comfortable feel.

The blade guards of the cutting machines are to beredesigned. These guards can be designed either asenclosure guards or as interlocking guards. Enclosureguards will cover the entire blade. Interlocking guardswill allow the machine to function only after the blade

guards are lowered.


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AN ERGONOMIC LAYOUT OFCUTTING ROOM

CONCLUSION
http://plant%20layout.docx/http://plant%20layout.docx/http://plant%20layout.docx/http://plant%20layout.docx/


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CONCLUSION During this project we came to know that ergonomics features

in the cutting rooms in most of the industries are very poor.

Our observation turns out that modern equipments and toolsare manufactured based on ergonomic designs andsuggestions.

But the cutting room work floor management and the building

layout do not support the concern of workers and ergonomics. These interventions made in the units would help to improve

the work environment of the garment manufacturing units.

This study demonstrates that there is ample room forergonomic improvements in the clothing industry.

We need to continue to identify problems and, moreimportantly, implement solutions to reduce the risk of injuries insituations where we know problems exist.

So, there is a huge scope of improvement in the field ofergonomics in apparel industry.


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REFERENCES

PDFS

Ergonomics In The Garment Manufacturing Industry

Ergonomics Awareness Training

Ergonomic Interventions To Improve Work EnvironmentIn Garment


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Thank you

cutting room ergonomics

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