This document provides an overview of OSHA regulations for the apparel and textiles industries with a focus on ergonomics. It discusses key departments in apparel like cutting, sewing, and finishing. It identifies potential ergonomic risks in tasks like scissors cutting, sewing, and quality inspection. Recommended solutions include adjustable workstations, automated equipment, job rotation and proper lighting/seating. The document aims to increase awareness of ergonomic hazards and musculoskeletal disorders as well as strategies to comply with OSHA regulations.

1. A Report on
OSHA Regulations for Apparel and
Textiles
2016
PREPARED BY:
ABHISHEK RAJ
SHRIYA ARORA
SARTHAK SAGAR
SUNIL KUMAR
DFT-VII
National Institute of Fashion Technology,
Chennai
Department of Fashion Technology
Ergonomics
GUIDEDED BY:
MR. A.O. ABDUL SALAM SAIT
ASSOCIATE PROFESSOR
DFT
NIFT, CHENNAI

2. 1
CONTENTS
 Introduction To Ergonomics
 Introduction To Occupational Safety And Health Administration
(Osha)
 Osha Regulations In Apparel Industry
 Osha Regulations For Textile Industry
 Manual Handling And Musculoskeletal Disorders (MSDs)
 References

3. 2
INTRODUCTION TO ERGONOMICS
 WHAT IS ERGONOMICS?
Ergonomics is designing a job to fit the worker so the work is safer and
more efficient. Implementing ergonomic solutions can make employees
more comfortable and increase productivity.
 WHY IS ERGONOMICSIMPORTANT?
Ergonomics is important because when you’re doing a job and your bodyis
stressed by an awkward posture, extreme temperature, or repeated
movement your musculoskeletal system is affected. Your bodymay begin
to have symptoms suchas fatigue, discomfort, and pain, which can be the
first signs of a musculoskeletal disorder.
 WHAT ARE THE ADVANTAGES OF ERGONOMICS?
1. Increasedsavings
• Fewer injuries
• More productive and sustainable employees
• Fewer workers’ compensation claims
– The average direct cost of a workers compensation claim for an MSD is
$14,120 (Oregon OSHA 2007)
– The indirect costs involved bring the total average claim costto well over
$32,000
2. Feweremployees experiencing pain
• Implementing ergonomic improvements can reduce the risk factors that lead
to discomfort.
3. Increasedproductivity
• Ergonomic improvements can reduce the primary risk factors for MSDs,
so workers are more efficient, productive, and have greater job
satisfaction.
4. Increasedmorale
• Attention to ergonomics can make employees feel valued because they
know their employer is making their workplace safer.
5. Reducedabsenteeism
• Ergonomics leads to healthy and pain-free workers who are more likely
to be engaged and productive.

4. 3
INTRODUCTION TO OCCUPATIONAL SAFETY AND
HEALTH ADMINISTARTAION (OSHA)
On December 29, 1970, President Nixon signed the OccupationalSafety and
Health Act of 1970
(OSH Act) into law, establishing OSHA. Coupled with the efforts of employers,
workers, safety and health professionals, unions and advocates, OSHA and its
state partners have dramatically improved workplace safety, reducing work-
related deaths and injuries by more than 65 percent.
In 1970, an estimated 14,000 workers were killed on the job – about 38 every
day. For 2010, the
Bureau of Labour Statistics reports this number fell to about 4,500 or about 12
workers per day.
At the same time, U.S. employment has almost doubled to over 130 million
workers at more than 7.2 million worksites. The rate of reported serious
workplace injuries and illnesses has also dropped markedly, from 11 per 100
workers in 1972 to 3.5 per 100 workers in 2010.
OSHA’s safety and health standards, including those for asbestos, fall
protection, cottondust, trenching, machine guarding, and benzene, lead and
blood borne pathogens have prevented countless work-related injuries, illnesses
and deaths. Nevertheless, far too many preventable injuries and fatalities
continue to occur. Significant hazards and unsafe conditions still exist in U.S.
workplaces; each year more than 3.3 million working men and women suffer a
serious job-related injury or illness. Millions more are exposed to toxic
chemicals that may cause illnesses years from now.
In addition to the direct impact on individual workers, the negative
consequences for America’s economy are substantial. Occupational injuries and
illnesses costAmerican employers more than $53 billion a year – over $1
billion a week – in workers’ compensation costs alone. Indirect costs to
employers, including lost productivity, employee training and replacement
costs, and time for investigations following injuries can more than double these
costs. Workers and their families suffer great emotional and psychological
costs, in addition to the loss of wages and the costs ofcaring for the injured,
which further weakens the economy.

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 OSHA’S MISSION
Congress created OSHA to assure safe and healthful conditions for working
men and women by setting and enforcing standards and providing training,
outreach, and education and compliance assistance.
Under the OSHA law, employers are responsible for providing a safe and
healthful workplace for their workers.
OSHA REGULATIONS IN APPAREL INDUSTRY
 DEPARTMENTSIN APPAREL INDUSTRY
 Cutting Department
 Sewing Department
 Pressing Department
 Finishing Department
 CUTTING DEPARTMENT
Employees working at manual scissorstations often have repeated exposure
to awkward wrist postures, repeated grip force, and contactstress to the hands
and fingers. This task may also require the employee to bend over a table and
reach with arms fully extended to cut the full length of the fabric. Scissorwork
may also include tedious or small range hand motions during finishing or
quality controltasks. Following are some possible risk factors involved in this
process, and possible solutions.
 Hand Postures
 Arm and Back Posture
 Repetition
1. HAND POSTURES
PotentialHazard:
 Holding the wrists in an awkward position while cutting with
scissors cancause injury to the wrist.

6. 5
Possible Solutions:
 Invest in tools designed to promote neutral joint postures (Fig 1).
 Use electric, pneumatic, or otherwise partially automated tools.
 Reduce the amount of force needed to operate tools by:
 Keeping tools well maintained (i.e., oiled and cleaned), and
 Instituting a tool sharpening program.
 Institute job rotation through tasks that do not require cutting with
scissors.
2. ARM AND BACK POSTURES
Potential Hazards:
 While cutting material, employees often bend over a table, which
may cause low back injuries (Fig 2).
 Employees must extend their arms to cut through a complete piece
of fabric (Fig. 2).
Possible Solutions:
 Use shorter-width tables so workers do not have to bend and
reach so far (Fig 2).
 Provide height- and tilt-adjustable tables; tables should be set at
elbow height.
 Feed fabric to the worker rather than making the worker reach for
the fabric.
Fig. 1

7. 6
 Use electric, pneumatic, or otherwise partially automated tools
(Fig 3).
 Institute job rotation through tasks that do not require bending at
the waist and cutting.
3. REPITITION
PotentialHazard:
 Cutting often requires employees to use repeated wrist motion,
grip force, and small range hand motions.
Possible Solutions:
 Reduce the amount of force needed to operate tools by:
 Keeping tools well maintained (i.e., oiled and cleaned), and
 Instituting a tool sharpening program.
 Invest in tools designed to promote neutral joint postures.
 Use electric, pneumatic, or otherwise partially automated tools
(Fig 4).
 Institute job rotation through tasks
that do not require cutting with
scissors.
Fig. 2 Fig. 3
Fig. 4

8. 7
 SEWING DEPARTMENT
Sewing 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. Forcemay also
be required to push fabric through the machine. Some of the common
risks and possiblesolutions associated with stitching are listed below:
 Moving Material to/from Workstation
 Setting Up Material
 Manipulating Material
 Stitching Material
1. MOVING MATERIALS TO/FROM WORKSTATION
Potentialhazards
 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.
 Workers bend/twist to pick up fabric (Fig. 4), which can hurt a
worker's back and shoulders.
Fig. 1 Fig. 2 Fig. 3 Fig. 4

9. 8
Possible Solutions
 Minimize overhead reach by:
Lowering the rack (Fig. 5); or
Placing station on platform or using height-adjustable portable clothing
racks or tables.
 Minimize reaches to the side or behind associated with picking up new
productor placing completed fabric by:
placing fabric/bins closer to the worker (Fig. 6);
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. 7), which allow workers to turn to get bundles and
pieces, rather than twisting to reach to the side or behind. Swivelling can
also make it easier for workers to sit down and get up from the
workstation
Fig. 5 Fig. 6 Fig. 7

10. 9
2. SETTING UP MATERIAL
PotentialHazard:
 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 properlighting:
Use adjustable task lighting to make it easier for the worker to see
productduring set up (Fig. 8).
Ensure bulbs are replaced frequently so they are functional at all times.
Provide properly positioned general overhead lighting
3. MANIPULATING MATERIAL
PotentialHazard:
 While manipulating fabric, employees repeatedly use a forceful pinch
grip (Fig. 9) between the thumb and index finger.
Possible Solutions:
 Use friction-increasing aids (Fig. 10) on fingers to reduce amount of force
exerted in the pinch grip.
 Analyse tasks to determine force requirement and use job/task rotation
through tasks not requiring pinch grip.
Fig. 8
Fig. 9 Fig. 10

11. 10
4. STITCHING MATERIAL
PotentialHazard:
 Employees push fabric through the sewing machine, which may require
extending arms, bending at the waist, and applying force (Fig. 11).
Possible Solutions:
 Use height adjustable tables (Fig. 12), 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.
 FINE WORK
Employees often perform fine work or tedious jobs at cutting, sewing, and
quality controlstations. Many times these jobs have acute visual requirements,
coupled with intense wrist, hand, and finger movements. Following are
potential risk factors and possible solutions involved in this process.
 Handling Tools and Fabric
 Visually Checking Work
1. HANDLING TOOLS AND FABRIC
PotentialHazards:
 Employees use a pinch grip to hold small scissors between the
index finger and thumb. Repeated pinch grip may cause hand or
wrist injuries (Fig. 1).
Fig. 11 Fig. 12

12. 11
 Holding small scissors between the index finger and thumb also
can cause contactstress on the fingers.
 While holding scissors ormanipulating fabric, employees often
maintain awkward arm, wrist, hand, and finger posture.
 Cutting and manipulating fabric requires the employee to use
repeated motions.
Fig. 1
Possible Solutions:
 Invest in tools designed to promote neutral joint postures and
minimize contact stresses (Fig. 2).
 Use electric, pneumatic, or otherwise partially automated tools to
reduce force and repetition of pinch grip (Fig. 2).
 Use tools and work practices that encourage workers to avoid
using more force and movement than the job requires.
 Use job rotation through tasks that do not require pinch grips.
Fig. 2
2. VISUALLY CHECKING WORK
PotentialHazards:
 Employees hold their neck, trunk, and arms in an awkward
position as they strain to see detail in an object (Fig. 3).

13. 12
 Insufficient lighting makes it difficult for employees to see their
work, and may cause eye fatigue and headache.
Fig 3
Possible Solutions:
 At the workstation, adjustable task lighting must shine on the
work area to make it easier for the worker to see the product(Fig
4).
 Provide adjustable chairs and training on how to properly use
them (Fig 4).
 Provide magnifying glasses at workstations where necessary (Fig
4).
Fig 4

14. 13
 Use height adjustable tables (Fig. 5) and sit/stand stools (Figs. 6 & 6a) to
allow employees to adjust their postures.
 For close work that is hard to see, the table should be adjusted 2 to
4 inches above elbow height. However, working at this height
might mean that workers have to work with their elbows raised,
which can make their shoulders and forearms uncomfortable.
Raised elbows should be supported with padded elbow rests.
 Institute job rotation.
Fig 5 Fig 6 Fig 6a
 SEWING STATION DESIGN
Employees encounter several risk factors at sewing workstations, such as
awkward arm, neck, trunk, and leg postures. These postures are influenced by
the size of the worker and the design of the workstation. This section explains
potential hazards encountered at the workstation and a general description of a
properworkstation design.
 Chair
 Table
 Treadle/Peda

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1. CHAIR
PotentialHazards:
 Workers often maintain awkward shoulder, elbow, and wrist
postures (Fig. 1) while sewing because of improper chair height
or position.
 Employees must sit or stand for long periods in the same position,
resulting in soreness of the back and neck, and/or buttocks, and
reduced circulation to the legs.
Possible Solutions:
Use easily adjustable chairs (Fig. 2) to minimize awkward postures, and
provide training on how to properly use them.
 Chairs should have:
 easily adjustable height, seat tilt, and backrest position;
 padded back rest with rounded edges that supports worker's
lower back;
 no wheels, or wheels that lock;
 a gently sloped or "waterfall" front edge to help prevent the
chair's edge from pressing into the back of the legs; and
 a cushioned/contoured seat, which distributes the worker's
weight so no bodypart gets all the pressure.
To choosea properchair, consider the amount of movement the task
requires, and the size of the worker. For tasks that require a lot of
twisting, Fig. 2 is desirable.

16. 15
 Chairs should be placed at an appropriate distance from the workstation,
so workers can perform tasks without pulling their elbows away from the
body(Fig. 3).
 Motor placement should not interfere with properchair distance.
 Chair height is correctwhen the work surface is at elbow height. Ideally,
in this posture, the entire sole of the foot should rest on the floor, and the
back of the knee should be slightly higher than the seat of the chair (Fig.
4). (This illustrates the importance of also having an adjustable table.)
The seat may be slightly lower when the worker uses a treadle or pedal.
 Provide sit/stand workstations, which encourage changing posture (Figs.
5 & 5a).

17. 16
 Provide anti-fatigue mats (Fig. 6) for workers who are standing for
prolonged periods. Anti-fatigue mats promotebetter circulation and
reduce fatigue in the lower extremities.
 Schedule frequent, short breaks to stretch and/or change position.
 Provide training on importance of breaks to help reduce injuries.

18. 17
2. TABLE
PotentialHazards:
 Workers maintain awkward shoulder, elbow, and wrist postures
while sewing because of improper table height (Fig. 7).
 Employees resting forearms or wrists on sharp edges may cut off blood
circulation, pinch nerves, and cause injury to the arms or hands (Fig. 8).
Possible Solutions:
 Provide both height- and tilt-adjustable tables (Fig. 9), which can
help employees access their work without using awkward
postures.

19. 18
 Tables should be adjusted so the work is at elbow height and wrists are
kept straight (Fig 10). If the table is too low, workers will have to hunch
forward, putting strain on the back, neck, and shoulders. If a table is too
high, workers will have to raise their shoulders to get their arms high
enough to work. This posture tires the neck, shoulder, and upper back
muscles and may result in muscle pain.
 For sit-down work, the table should also be high enough to allow room
underneath for the worker's legs (Fig. 11). The table top should not press
on the worker's thighs. Workers who use a treadle need more room than
those who don'tso they can move their legs more easily.
 Tables may be tilted slightly toward workers, to enable them to see the
work more easily and to reduce awkward wrist postures (Fig. 12).
 When sewing heavy fabric, the table may be tilted away from the worker,
which may help pull the fabric through the machine and lessen manual
force applied by the worker.

20. 19
 Edges of work surfaces should be padded or rounded, so workers can rest
their arms against them (Fig. 13).

21. 20
3. TREADLE/PEDAL
PotentialHazards:
 Employees operating a treadle for prolonged periods must
maintain awkward and unbalanced posture (Fig. 14).
 Employees required to apply a constant treadle force must
maintain static lower extremity postures.
 Workers may also maintain poorpostureif treadle is too close or
too far away (Fig. 15).
Possible Solutions:
 Design treadle to require less force (Fig. 16), allowing the use of a
sit/stand workstation.
 When feasible, use hip switches or redesigned foottreadles to
eliminate the need to apply constant standing pressure.

22. 21
 Provide adjustable treadle so the worker can place it in a
comfortable position and get as close to the table as possible
(Fig.17).
 Use job/task rotation through tasks that do not require constant leg
pressure and awkward leg posture.

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OSHA REGULATIONS FOR TEXTILE INDUSTRY
 Manual Handling in Textile Industry – The Problems
Musculoskeletal problems often stem from poorwork place or job
design. Among the most common examples of risky activities include:
o heavy or awkward loads;
o difficulty in gripping;
o excessive use of force;
o repetition; and
o twisting and other awkward postures.
Some of these problems linked to the textile industry are outlined in more
detail below, together with possible solutions
 Handling bales
o Location
 Usually in delivery and storage areas
o Problems
 Bales are generally too heavy to be handled without
mechanical help
 Manual movement of bales can present a serious risk of
injury, even the use of hand trucks should be kept to a
minimum
o Solutions
 use more than one worker to do the job, particularly when
getting the bale onto a truck
 use hand hooks to grip the bale
 use lift and clamp trucks, roller conveyors, appropriate hand
trucks
 maintain floor surfaces
 Handling bundles of processedfibre
o Location
 Packaging areas and close to carding and gilling machines
o Problems
 size, shape and weight of bundle (typically 9 to 22 kg)
 repetitive nature of the task

24. 23
 reaching and stooped postures adopted when lifting from
bins
 forces needed to pull and manoeuvre bundles before lifting
 container bins are often used to collect bundles before they
are transferred to packing containers - the worker has to lean
and reach into the bin to grasp the bundle
 the build-up of bundles also adds to the physical effort
needed to pull and lift them clear of the bin
o Solutions
 improve access to the bundles, eg with removable sections
on the sides of collection bins
 ensure bundles can be lifted from waist height and close to
the body
 if possible, install a direct conveyor belt from the collector
bin to the packing container
 consider carefully the way work is organised, eg:
 move workers between a number of different jobs (job
rotation)
 increase the range of tasks within a job to lengthen the
handling cycle (job enlargement)
 provide recovery time where handling is not used
 Handling rolls
o Location
 often close to machinery, eg lifting to and from weaving
machines
 in storage and despatchareas, eg lifting to and from shelves,
racks, trolleys and stillages
 in quality controlareas, eg weighing
o Problems
 weight and size of roll
 awkward postures adopted due to lack of space(reaching)
 stooping and twisting, especially if lifting from a low level
 grasping difficulties, where it is often necessary to change
the grip during the lift
 when lifting and handling in teams of two or more people:
 uneven distribution of weight between individuals
 differences in strength and stature
 difficulties in co-ordinating the lift
o Solutions

25. 24
 consider mechanical methods of handling the rolls, for
example: a conveyor
 mounting roller tracks on table tops means that the rolls can
be maintained at a comfortable working height
 the rolls rest on smooth, flat, lightweight boards, reducing
friction, as well as preventing the cloth from being damaged
 organise rolls according to weight so that heavier rolls are
stored at a convenient height for handling
 consider using a simple lifting arm to raise rolls onto a work
surface
 consider using an automated conveyor system to transport
rolls to despatch
 a gap in the conveyor will allow workers to pick up the roll
up at its balance point, before carrying it to the vehicle; the
conveyor can be used by left- and right-handed people
 designing the layout of the work area is most important, bear
in mind
 the need to use maximum capacity in storage areas often
means that access to items is difficult
 planning and good house-keeping will help reduce the
likelihood rolls being presented at shoulder height
 Handling looselyfolded cloth
o Location
 Common to a number of intermediate stages of the
production process,eg moving cloth to or from machines,
inspection and quality controlareas, including lifting to or
from weighing scales
o Problems
 the weight of the cloth
 its unstable nature, eg its tendency to sag, which results in
more effort when lifting onto raised surfaces becausearms
must be raised so much higher than the work surface
 the difficulties of ensuring a firm grasp on the load
 the problems associated with people lifting in teams
o Solutions
 a lightweight ‘stretcher-board’ which not only reduces the
distance through which the load is lifted but also improves
its stability and provides for a more even distribution of
weight between two lifters (the board also has suitably

26. 25
designed hand-holds which improve grip and the ability to
apply the necessary force during the lift)
 a weighing scale mounted into the floor close to the
workstation - rather than transferring cloth onto weighing
scales and then putting it onto storage trolleys, the loaded
trolley can be wheeled onto the scale for the cloth to be
weighed, removing the need to lift the cloth
 Handling boxes
o Location
 Mainly in delivery and storage areas, including to and from
vehicles
o Problems
 size, shape and weight of boxes
 awkward and constrained postures when lifting to and from
storage racks
 difficulty grasping the load securely
o Solutions
 a system suspended onan overhead rail, the device is free to
move within the storage area
 pneumatic grippers grasp the box securely and scales
built into a roller conveyor compensate for the weight
of the load, allowing it to be moved with minimal
effort
 the device can be adapted to suit a range of different
items and containers
 vacuum-operated handling/lifting equipment
 consider mounting weighing scales in the floor or,
alternatively, increasing the height of the surrounding work
area to bring it in line with the height of the weighing scales
 conveyor belts offer flexible and effective means by which
to transport packaged material over long distances - these
can be powered or non-powered and are available with
flexible telescopic arms which can be adjusted to suit a range
of different applications (the angle of the extended arm can
be easily adjusted to suit the height at which the boxes are
passed to the conveyor belt)
 speak to suppliers to try and identify a packaging design that
best suits the manual handling devices available

27. 26
 Lifting to and from bins, stillages, trolleys and machinery
o Location
 Found in most areas but particularly common close to
machinery
o Problems
 Awkward trunk postures when lifting from the bottom of
bins, trolleys and stillages with rigid sides (eg bucket
trolleys)
o Solutions
 trolley fitted with a self-levelling base
 the base is suspended from each corner of the trolley by four
springs and, as material is removed, the suspended base
rises, maintaining a constant height from which to lift (the
oppositeoccurs when material is added)
 an inner lining prevents material from being caught in the
springs - spring tension can be varied depending on the
weight of the material being carried
 if self-levelling bucket trolleys are unsuitable, then consider
whether improved access to the base of the trolley can be
achieved by providing drop-downsides or tilting the trolley
towards the worker
 Handling of cones to and from boxes
o Location
 Cones of spun yarn being removed from a conveyor and
replaced by empty bobbins
o Problems
 Awkward postures, eg bending and reaching sideways into
the bottom of the stillage
o Solutions
 tilting platforms enable both trolleys to be angled towards
the worker allowing easier access to the contents
 raising the height of the conveyor track and providing
suitable seating also improve the posture the personadopts
throughout the handling operation
 Moving drums of dye
o Problems
 Awkward handling postures
o Solutions

28. 27
 A simple purpose-madetrolley, ie a trolley with its base at
the same level as the raised storage shelf, making the transfer
of drums easier (this kind of trolley can only help where the
floor is suitable; the wheels will need to be maintained so
that they run smoothly)
 Working around machinery
o Problems
 Awkward and forceful postures often stem from the way
people interact with machinery
o Solutions
 Modifying machinery is expensive but simple tools to assist
handling can provide a cost-effective alternative, eg hand
tool designed to lock onto the head of the bobbinallows the
hand and arm to adoptmuch more suitable positions
 Handling heavy yarn packages
o Solutions
 use a mechanical handling device suspended from an
overhead supportor rail that grips the centre of the package
and, by balancing and supporting the load, helps with lifting
and manoeuvring the packages
 it is important to consider the size of individual users in
relation to the machinery that they operate
 if one personhas responsibility for one or several pieces of
machinery, then ensure that the handling aids provided are
suitable for the individual
 where several operators use the same machinery, then
consider handling aids which can be adjusted easily
 Maintenance
o Problems
 Maintenance tasks can lead to some of the most hazardous
handling operations:
 often performed in confined and restricted space in and
around machines
 while many are routine and frequently undertaken, some are
more varied and unpredictable requiring more effort to plan
and controlthe activity

29. 28
 some tasks require workers to supportheavy components
while bolts are removed or replaced
 the main risk factors are the weight of the componentparts
(often in excess of 50 kg), restricted access and consequent
awkward postures, and insecure footing
o Solutions
 planning during machine installation, eg by allowing access,
providing overhead hoists and lifting points such as eyebolts
 otherwise, flexible multi-purpose handling devices can be
more practical than alterations to the workplace
 mobile hoists and even motor vehicle jacks can provide
mechanical assistance
 aim to minimise handling requiring changes in height and
the supporting of heavy loads
 handling tool boxes is often taken for granted and yet this
too can involve repetitive lifting of heavy loads, usually with
one hand – consider using a simple tool-box trolley
 good maintenance also includes the regular upkeep of
machinery and good housekeeping, eg trolleys are used
extensively throughout the industry and play a major part in
reducing manual handling - however:
 poorly maintained wheels can become clogged with waste
material or stick due to wear, increasing the force that must
be exerted to move them
 systematic cleaning and maintenance of wheels, perhaps
including a simple record, will help ensure that risks of
injury are minimised.
 well-maintained floors will also benefit the users of trolleys
 Manual handling and Musculoskeletal Disorders (MSDs)
o Musculosketal disorders (MSDs) are one of the biggest causes
of injuries in textiles.
o Injury and health problems show up in different ways, such as:
o injury to backs and limbs
o aches and pains
o poor product quality
o high material waste

30. 29
o low output
o frequent worker complaints and rest stops
o do-it-yourself improvements to workstations and tools (eg seat
padding)
o workers wearing bandages, splints, rub-ons, copper bracelets
or magnets
 Musculoskeletal disorders
o The term MSD covers any injury, damage or disorder of the
joints or other tissues in the upper/lower limbs or the back.
This website provides advice to prevent and manage MSDs,
including tools to assess the risks of manual handling and
repetitive tasks.
o Musculoskeletal disorders may be characterized by pain,
numbness, and a lack of mobility in the affected area, usually
the hands, shoulders, and back.
 Types of Musculoskeletal disorders
o Upper limb disorders
o Lower limb disorders
o Back pain
o Other conditions (HAVS, RSI, WBV etc)
 Upper limb disorders
o Upper limb disorders (ULDs) affect the arms, from fingers to
shoulder, and neck. They are often called repetitive strain
injuries, 'RSI', cumulative trauma disorder or occupational
overuse syndrome.
o Are aches, pains, tension and disorders involving any part of
the arm from fingers to shoulder, or the neck
o include problems with the soft tissues muscles, tendons and
ligaments, along with the circulatory and nerve supply to the
limb; and
o are often caused or made worse by work
o The way the work is organised and managed can make a
significant contribution to reducing the risk of ULDs as well as

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make them worse.
 Upper limb disorders – Symptoms
o tenderness
o aches and pain
o stiffness
o weakness
o tingling
o numbness
o cramp
o swelling
 Upper limb disorders – Causes
o Repetitive work
o Uncomfortable working postures
o Sustained or excessive force
o Carrying out a task for a long period of time
o Poor working environment and organisation (eg temperature,
lighting and work pressure, job demands, work breaks or lack
of them)
o Individual differences and susceptibility (some workers are
more affected by certain risks)
o The way the work is organised and managed can make a
significant contribution to reducing the risk of ULDs as well as
make them worse.
o Workers may be more likely to suffer an upper limb problem
if exposed to more than one risk factor.
 Upper limb disorders – Preventions
o Because most injury happens as a result of incorrect posture,
working in unusual positions, or heavy lifting/carrying the
most effective way to reduce the risk is to:
o Provide/use mechanical aids
o rotate staff to reduce the time spent carrying out a 'risky' task
and give time for recovery
o have regular breaks

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o Where possible, provide proper seating and risk assess
workstations to identify potential problems and tackle those
problems – particularly where you are using a computer or
other piece of static equipment.
 Lower limb disorders
o Lower limb disorders (LLDs) affect the legs from hips to toes.
The most common risk factors at work are:
o repetitive kneeling and/or squatting
o fixed postures such as standing for more than two hours
without a break
o frequent jumping from a height
o Osteoarthritis (OA)
 Osteoarthritis (OA) is a degenerative condition that
affects the joints of the body (eg knees, hips and spine),
and happens when the cartilage coating at these joints
becomes damaged or worn away. Hip OA is more
common among male than female workers and farmers
have a significantly higher risk of suffering from it.
There is a significantly increased risk of knee OA among
miners, floor layers and cleaners.
o Knee bursitis
 Knee bursitis - also called coal miner's, carpet layer's or
housemaid's knee - is caused by repetitive kneeling or
knee-straining activities. Workers who develop bursitis
generally report tenderness and swelling, and a reduction
in knee movement due to pain and tightening of the skin
over the kneecap.
 Beat knee or hyperkeratosis is the thickening of the skin
over the knee due to pressure. It is an acute and extreme
form of bursitis and is common among those regularly
involved in knee-straining activities, such as kneeling
and squatting.
o Meniscal lesions/ tear damage
 If the knee is bent or twisted while bearing a load, the
force may cause meniscal lesions or damage to occur.
Overuse trauma, for example repetitive squatting or

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kneeling, can also cause meniscus injury or damage.
Such damage leans toward the injured knee being
inclined to degenerative changes typical of OA.
o Stress fracture/stress reaction injuries
 Stress fracture and reaction injuries are the result of
repeated micro-injuries to bone, typically found in those
who regularly undertake marching or stamping of the
feet. They are more common in people undergoing
military training and in athletes, particularly long-
distance runners.
o Varicose veins
 Varicose veins are any dilated subcutaneous veins of the
leg. Employees may complain of feelings of heaviness
and pain, a sensation of swelling of the legs, night time
calf cramps and restless legs. These complaints can
increase during the day, especiallyafter prolonged
standing.
 Lower limb disorders – Causes
o Lower Limb Disorders (LLDs) at work affect the hips, knees
and legs and usually happen because of overuse - workers may
report lower limb pain, aching and numbness without a
specific disease being identified.
o Acute injury caused by a violent impact or extreme force is
less common. However, athletes and military personnel are
more prone to these injuries so workers who take part in these
activities may report them at work.
o Scientific evidence suggests that there are several recognised
diseases of the lower limb which can be work related such as:
hip and knee osteoarthritis; knee bursitis, meniscal
lesions/tears; stress fracture/reaction injury and varicose veins
of the lower legs.
 Lower limb disorders – Symptoms
o Pain, tenderness or stiffness of the joint, unable to straighten or
bend those joints.

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o Tenderness aches and pains, stiffness, weakness, tingling,
numbness, cramp and swelling to the muscles of the lower
limbs.
o These symptoms may suggest overuse or some underlying
condition and, if you are concerned, seek advice from your
Doctor.
 Lower limb disorders – Preventions
o Because most injury happens as a result of overuse, the most
effective way to reduce the risk is to avoid overuse by
providing/using mechanical aids or rotate duties to reduce the
time spent carrying out a 'risky' task and give time for
recovery.
o Where possible, provide seating rather than requiring squatting
or kneeling and have regular breaks. Provide personal
protective equipment such as:
 Knee pads to protect the knee while kneeling on hard
floor surfaces and preventing lacerations and penetrating
injuries and improving comfort.
 Anti-fatigue matting may be effective in reducing the
risks from prolonged standing. But using the mats in the
workplace requires careful consideration because of the
increased risk from slips and trips.
 Shock absorbing insoles and modified shoes: There is
limited evidence that using these aids reduces the
risk. The positive effects are mainly in respect of
injuries from vertical impact loads.
 Back pain
o Low back pain is common and can be extremely painful. It can
be difficult to cope with the severe pain but fortunately it is
rarely due to serious disease. There are things that employers
and workers can do to manage back pain and other
musculoskeletal disorders (MSDs), in the workplace. People
can be helped to remain in work or helped to make an earlier
return to work.

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o Most back pain is not caused by any serious damage or
disease. The pain usually improves within a few weeks, at
least enough to allow you to get on with your life.
o Suffering from back pain does not mean you must
automatically be off work. Inactivity and bed rest can increase
the chance of disabilityso it is in your interest to remain active
unless your doctor tells you not to.
 Back pain – Symptoms
o Difficulty passing or controlling urine
o Numbness around your back passage or genitals
o Numbness, pins and needles, or weakness in both legs
o Unsteadiness on your feet
 Back pain – Preventions
o Take steps to reduce the risk of back pain in the workplace.
o You could:
 Think about how you can make jobs physically easier,
e.g. by moving loads on wheels, providing better handles
on loads, adjusting heights of worktops etc.
 Consult regularly with the employees on their health and
well being to help you identify concerns and developing
trends.
 Take actions to address any outcomes from these
discussions.
 Respond promptly when an individual worker reports
back pain
 Do risk assessments – and make changes where needed.
 Other conditions
o Repetitive Strain Injury (RSI) -
 This is usually an upper limb disorder caused by doing
the same task (typing, twisting, bending etc) over and
over again. It can be more damaging where a load is
involved in the task.
o Hand Arm Vibration Syndrome (HAVS) -

36. 35
 This is usually the result of using hand-held power tools
regularly.
 Symptoms include tingling and numbness in the fingers
(which can cause sleep disturbance), loss of
feeling/strength in fingers or the tips of the fingers going
white, particularly in cold weather.
 If you continue to use high-vibration tools these
symptoms will probably get worse, and could result in
more frequent symptoms or permanent numbness in
your hands and lost feeling which could lead to
difficulty picking up small objects such as screws or
nails
o Vibration White Finger - Another name for HAVS.
o Osteoarthritis –
 This is the most common form of arthritis, although it
usually occurs in older people, it's often caused by wear
and tear.
 It can be the result of joint damage from an injury or the
repair that occurs after the injury.
 Osteoarthritis usually occurs in the last joints of the
fingers, at the base of the thumb, in the knees, big toes
and feet.
 An injury at any stage in life can cause arthritis.
o Carpel tunnel syndrome (CTS) -
 This is a relativelycommon condition that causes pain,
numbness and a burning or tingling sensation in the hand
and fingers.
 The carpal tunnel is a small tunnel that runs from the
bottom of the wrist to the lower palm. Several tendons
that help to move the fingers pass through the carpal
tunnel as does the median nerve, which controls
sensation and movement of your hand.
 Examples of activities that may lead to CTS include:
 playing a musical instrument
 assembly packing
 using a computer keyboard
 craftwork (making decorative items by hand)

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 work that involves manual labour
 Process for Protecting Workers
o Provide Management Support
o Involve Workers
o Provide Training
o Identify Problems
o Encourage Early Reporting of MSD Symptoms
o Implement Solutions to Control Hazards
o Evaluate Progress
 Solutions to Control Hazards
o Many industries have successfully implemented ergonomic
solutions in their facilities as a way to address their workers'
MSD injury risks.
o These interventions have included modifying existing
equipment, making changes in work practices and purchasing
new tools or other devices to assist in the production process.
o Making these changes has reduced physical demands,
eliminated unnecessary movements, lowered injury rates and
their associated workers' compensation costs and reduced
employee turnover.
o In many cases, work efficiency and productivity have
increased as well. Simple, low-cost solutions are often
available to solve problems.
o Use the information on this page to see what has worked for
others in your industry or in other industries.
 Overview of Controls for MSD Hazards
o To reduce the chance of injury, work tasks should be designed
to limit exposure to ergonomic risk factors. Where possible,
engineering controls are the most desirable.

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o Administrative or work practice controls may be appropriate in
some cases where engineering controls cannot be implemented
or when different procedures are needed after implementation
of the new engineering controls.
o Personal protection solutions have only limited effectiveness
when dealing with ergonomic hazards.
 Engineering Controls
o implement physical change to the workplace, which
eliminates/reduces the hazard on the job/task
 E.g:
o Use a device to lift and reposition heavy objects to limit force
exertion
o Reduce the weight of a load to limit force exertion
o Reposition a work table to eliminate a long/excessive reach
and enable working in neutral postures
o Use diverging conveyors off a main line so that tasks are less
repetitive

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o Install diverters on conveyors to direct materials toward the
worker to eliminate excessive leaning or reaching
o Redesign tools to enable neutral postures
 Administrative and Work Practice Controls
o establish efficient processes or procedures
 E.g:
o Require that heavy loads are only lifted by two people to limit
force exertion
o Establish systems so workers are rotated away from tasks to
minimize the duration of continual exertion, repetitive
motions, and awkward postures. Design a job rotation system
in which employees rotate between jobs that use different
muscle groups
o Staff "floaters" to provide periodic breaks between scheduled
breaks
o Properly use and maintain pneumatic and power tools
 Personal Protective Equipment
o use protection to reduce exposure to ergonomics-related risk
factors
 E.g:
o Use padding to reduce direct contact with hard, sharp, or
vibrating surfaces
o Wear good fitting thermal gloves to help with cold conditions
while maintaining the ability to grasp items easily

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REFERENCES
 http://www2.worksafebc.com/Topics/Ergonomics/Resources-
general.asp
 http://www.hse.gov.uk/textiles/textiles-and-manual-
handling.htm
 http://www.hse.gov.uk/textiles/manual-handling.htm
 http://www.hse.gov.uk/msd/index.htm
 https://www.osha.gov/SLTC/ergonomics/controlhazards.htm
l
 Ergonomics for Beginners (3rd
Edition)– Jan Dul and
Bernard Weerdmeester
 Introduction to Ergonomics (3rd
Edition)– R.S Bridger