Proceedings of the National Conference on

Trends and Advances in Mechanical Engineering,

YMCA Institute of Engineering, Faridabad, Haryana.., Dec 9-10, 2006.

ERGONOMIC PARAMETER DESIGN FOR SEWING MACHINE

WORKSTATION USING WORKERS PERCEPTIONS
Balraj Singh Brar1, S.Manjit2, S.S.Chaha3, S.Harpreet4
1,2,3,4
Department of Mechanical Engineering, Bhutta College of Engineering and Technology, Bhutta, Ludhiana,
Punjab-141026, India
Phone: 098144-37802, 1Email: balrajsinghbrar@gmail.com, balrajsinghbrar@yahoo.com

Abstract
Ergonomic 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 and
comfortable. 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 include different modules; 1) Perceived posture 2) localized postural discomfort 3)
estimated endurance time. Workers perceptions were analyzed by finding their criticality 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 Parameter Design, Localized Postural Discomfort, Perceived Posture, Sewing Machine
Workstation, Workers Perceptions

1.0 Introduction
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. 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; fit man and machine together.

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
sewing machine workstation. The efforts were made to make the sewing machine workstation ergonomically fit to
create or to 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 machine
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 improper chair height or position. A typical treadle sewing
machine workstation includes work surfaces, space for all activities and components of the task, seating for operator,
desk for sewing operation, and pedal for operating foot. A treadle sewing machine is operated by the sewing
operator, by using the foot pedal

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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 well-designed, convenient sewing area large or small saves time and energy. It
does not have to be whole room dedicated just to sewing. It can be seldom-used closet, an out-of-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 recommended parameters of the sewing machine.

2.0 Methodology
This study is purely based on 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 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 was 162cms-172cms. The average height of the worker was 165cms.
c) Weight: The average weight of the worker was 74 kgs.
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 favourable, 3= favourable, 5= unfavourable, 7= very unfavourable. Scores of 2, 4 and
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 the body using a scale ranging from 0 (no
discomfort) to 5 (very severe discomfort).

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 Proceedings of the National Conference on
Trends and Advances in Mechanical Engineering,
YMCA Institute of Engineering, Faridabad, Haryana.., Dec 9-10, 2006.

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 8 hours, 2=
6-8 hours, 3= 4-6 hours, 4=2-4 hours, 5=less than 2 hours).

3.0 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:
Criticality index = XiYi

Xi
Where Yi = perceptions of the workers in specific category
Xi = weightage given to each point scale
As shown in table 1 and Figure1, 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 .
*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.

Table 1. Response rate of workers for Perceived posture

Parameter* Posture Posture Posture Posture Posture Posture of Posture Posture Posture Posture
of of back of of of right of left of right of left of right
neck left right left upper upper lower lower foot foot
shoulder shoulder arm arm leg leg (I) (J)
(A) (B) (C) (D) (E) (F) (G) (H)
1 32 23 47 46 49 49 40 40 50 50
2 06 08 05 05 06 06 06 06 02 02
3 54 46 46 47 43 43 41 41 39 39
4 02 05 02 02 02 02 04 05 02 03
5 05 16 00 00 00 00 09 08 05 05
6 00 01 00 00 00 00 00 00 02 01
7 01 01 00 00 00 00 00 00 00 00
Criticality
index 8.78 10.35 7.25 7.32 7.07 7.07 8.42 8.39 7.71 7.64

3.2 Localized Postural Discomfort

The operator was asked to rate his postural discomfort in the different parts of a human body using scale ranging
from 0 (no discomfort) to 5 (very severe discomfort). After getting 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 right leg (Criticality
index = 1.73), discomfort of upper neck/back (Criticality index = 1.66). There is a need to give attention on these
discomfort body parts.

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 Table 2. shows the perception of operators about localized postural discomfort
No. of operators rated their perception

Parameters A B C D E F G H I J
No discomfort 91 94 58 86 90 99 97 81 81 40
Some discomfort 07 03 25 07 05 00 02 13 14 42
Minor discomfort 01 01 14 03 03 01 01 03 03 15
Major discomfort 01 02 03 04 02 00 00 02 02 02
Severe discomfort 00 00 00 00 00 00 00 01 00 01
Very severe discomfort 00 00 00 00 00 00 00 00 00 00
Criticality index 0.8 0.73 4.13 1.66 1.13 0.13 0.26 1.93 1.73 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.

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

4
2
0
A B C D E F G H I J
Fig. 1 shows the criticality index of the perceived postures

6 5.46
5 4.13
4
Criticality
Index 3 1.93 1.73
1.66
2 1.13
0.8 0.73
1 0.13 0.26
0
A B C D E F g H I J
Fig.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.

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 Proceedings of the National Conference on
Trends and Advances in Mechanical Engineering,
YMCA Institute of Engineering, Faridabad, Haryana.., Dec 9-10, 2006.

Between 2-4
5%
Between 4-6
14%

More than 8
39%

Between 6-8
42%

Fig. 3 shows endurance time of sewing machine operators

3.4 Parameters for Sewing Machine Workstation Design

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, 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).

Table 3 shows recommended Parameters corresponds to critical areas

S.No. Critical areas Recommended parameters

1 Posture of back/neck Desk slope, Desk Height
2 Posture of left lower leg Pedal position
3 Posture of right lower leg Pedal Position
4 Discomfort of whole body Desk height, Desk slope, Pedal position

4.0 Conclusion
It has been concluded that there is a need of ergonomically fit sewing 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.

Acknowledgement
This study will play important role while designing the sewing machine workstation for the operators, to make
the healthy working environment. This study is carried out by considering the treadle sewing machine, which is
used by the sewing machine operators for doing their work. The authors are lecturers in the department of
mechanical engineering of Bhutta College of Engg. & tech., Bhutta, Ludhiana. The authors wish to thank the
Research and development centre for Bicycle parts and Sewing Machine, Ludhiana, who helped to inspire and
complete the research work.

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