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“WORK STATION DESIGNING”
PROJECT REPORT
Submitted for PBL in Industrial Engineering(FST3003)
By
R PRIYANGA(16BFT1004);
N SARANYA(16BFT1006);
RITUPARNA MODAK (16BFT1012);
P AMIRTHA VARSHINI(16BFT1015).
Slot:C1
Name of faculty: Ms. N Gayathri
VIT FASHION INSTITUTE OF TECHNOLOGY
March, 2019
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CERTIFICATE
This is to certify that the Project work entitled “WORK STATION DESIGNING” submitted
byR.Priyanga(16BFT1004),N.Saranya(16BFT1006), Rituparna Modak (16BFT1012), P.Amirthavarshini
(16BFT1015)to VIT University, Chennai Campus, in partial fulfillment of the requirement for the award of the
degree B.Tech in Fashion Technology undertaken by her under my supervision for the subjectIndustrial
Engineering(FST3003).The project completed the requirements as per the regulations of this Institute and inmy
opinionthe necessary standards for submission. Itis a record of bonafide work done under my supervision. The
contents of this Project work have not been submitted for any other PBL course.
Signature of Faculty: Prof. N Gayathri
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ACKNOWLEDGEMENT
The success and the final outcome of this project required of guidance and assistance from many people and we
are extremely fortunate to have got this all along the completion of our project work. Whatever we have done is
only due to such guidance and assistance and we would not forget to thank them. I respect and thank Prof. N
Gayathri for giving us an opportunity to do this project and providing us all the support and guidance which
made us complete the project on time. We are extremely grateful to them for providing such nice support and
guidance. We would also like to thank VIT University, Chennai for giving us an opportunity to do this project.
This project cannot be completed without the effort and cooperation of our group members. Last but not the
least we would like to thank our friends for helping us in completion of the project within the limited time
frame.
Place: Chennai R PRIYANGA(16BFT1004);
Date: 3/04/2019 N SARANYA(16BFT1006);
RITUPARNA MODAK (16BFT1012);
P AMIRTHA VARSHINI(16BFT1015).
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ABSTRACT
India is agreed to carve a name for it as a hub for export oriented garment manufacturing centre globally. Many
researches prove that the garment industry is the largest manufacturing sector in India. Reports also state that
the workers in the apparel hub go through a lot of enck pain, lower back pain etc. Thus a good ergonomics is
very important for the workers to experience so that they can they can work effectively and make the apparel
hub as the leading hub in the world. Through literature review done based on the works carried out majorly in
India, it is found that the poorly designed workstation contribute to give trauma disorders which involves
musculoskeletal disorders of the upper limbs, shoulders and neck. The main aim of this paper is to reflect upon
the work station designs which directly relates to the good ergonomics so that the workers can work efficiently.
Good ergonomics makes it very better for the workers to work very efficiently which again relates to numerous
factors that should be improved so that the efficiency can be increased. To recognize ergonomics risk factors in
the work place is an essential step in correcting the hazards and improving worker protection. For the worker
protection factors like proper layout of the work station, proper arrangement of the table and chair, arrangement
of the machines etc should be considered while effectively designing the work station.
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1. INTRODUCTION:
Work Station is a place where operators perform their job. It is the place where operators find their equipments
to finish their task. Thus the work of the operators completely depends upon the work station that is the facility
and the environment that the operator has to work for. A well designed work station is very important for the
productivity of the work that is done by the operators. The work station should be designed according to the
needs of the individual workers depending upon the type of workers and the task that they do. The work station
should be designed keeping in mind the machineries that are used and the machines that are continuously
operated by the workers. A well-organised work station should be well-lit, free from the noise, chemical
hazards. That provides comfort zone for the workers to work, involves minimal material handling and thereby
reduces fatigue and increases the efficiency of the workers. To design the work station several factors are
considered. The layout is the major factor of work station design which involves the design of the arrangement
of the workstation like the placement of the machineries, chairs, tables, support for the body parts while
working in the machines, equipments arrangements ets. There are different types of layout used in apparel
industry such as process layout, line layout, combination layout, u-shaped layout etc. According to the layout
chosen the required arrangements can be done, so that the operators can frequently use the tools in the usual
work area and can reach without stretching. The tools such as nippers and scissors that are used frequently can
be attached to the machine. The other small items such as buttons, hooks etc can be kept in a separate place with
a label on each section for clear identification. The sitting position of the operators is a major factor of lower
back pain, nekc pain etc that can be improved by a good work station design by providing a backrest and a
comfortable foot rest so that workers get it easy to work on the machines. There should be adequate leg room as
well so that workers can change their leg position every time they want. To consider the height of the work
benches, it should be designed in such a way so that workers can keep their arms low and elbows close to the
body. Appropriate lighting is very essential for the workers to work in the sewing machine. Lighting should be
bright to an extent so that it allows an easy and clear visibility for the workers rather than glaring at the workers
eyes. Ventilation is an important part so that there does not occur suffocation when the workers are working.
Along with the light bulbs that are used there should be provision for the natural light to pass through as this
gives comfort to the eyes during the early morning hours. Waste clearance provision should be there in the
apparel industry due to high accumulation of sewing wastes when inhaled causes lungs and breathing problems.
Features in the garment industry can be improved by communication, involvement among the employees in
decision making, education and training of employees and management on prevention strategies and the
ergonomics conditions at the plant. The clothing industry is generally seen as a safe place to work when it is
taken in comparison to other industries. Thus the factors that can relate to reduce the injury rates includes
empowerment of the workforce, higher seniority of the workforce, safety protocols, better house keeping and
active role of top management so that the designed work station efficiently functions to increase and continue
the productivity of the industry.
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2.LITERARURE REVIEW:
“The paper proposes a literature review on workplaces ergonomic effective design in the manufacturing systems
and industrial plants sector. The main objective is to provide the reader with an accurate overview on the main
scientific approaches proposed (during the last decades) by researchers and scientists working in this specific
area. The paper passes through the description of several research works as they run through the literature. The
initial search identifies a huge number of articles which were reduced to about 50 studies based on content and
quality. The descriptive analysis of the literature reveals heterogeneity in the content of the scientific
approaches due to the different principles, methods and tools applied for improving the interaction between
humans and their working environment. Workstation partitions are used in open plan offices for many reasons
and come in a wide variety of materials, types, and shapes. The position, height, and orientation of partitions
affect the amount and distribution of daylight entering a building as well as all forms of thermal transfer through
windows. However, these potential impacts cannot be determined if not adequately addressed in guidelines and
standards, and could mislead decision-making during design stages and hamper the refinement of office
furniture manufacturing. This study outlines exploring partition design, open offices, lighting and daylighting
quality, and codes and standards in detail which helps draw attention to the possible partition layouts that are
both effective and economical to overcome glare and visually uncomfortable conditions in open plan offices.
More widespread application of daylight-based partition design in open plan offices could result in a better
understanding of their performances, as well as improvements in their overall efficiency.”
-shikdar, (2004),
“Workplaces traditionally have been designed to move products or support machines efficiently. Since
people have always seemed so adaptable, how they fit into the workplace has received less attention. The
increasing number of injuries caused by repetitive motion, excessive force and awkward postures, ergonomics
has become a critical factor in workplace safety. According to Hagberg et al. [9], ergonomics and human factors
are often used interchangeably in workplaces. Both describe the interaction between the worker and the job
demands. The difference between them is ergonomics focuses on how work affects workers, and human factors
emphasize designs that reduce the potential for human error. While Bongers et al [10] stress that by addressing
traditional and environmental risk factors, it can keep workers injury free. Risk and risk factors are common
concepts used in safety and applied ergonomics literature. Risk includes a component of how likely or what the
probability of an event is and the seriousness of the consequence or what the severity is if something does occur.
Risk is often defined on how many injuries or accidents resulted for a given exposure. At the extremes, injury
risk can be viewed as very low probability but extremely high consequence (e.g.: multiple fatalities) or higher
probability but less severe consequence (e.g.: a worker slipping and tripping. Risk is also intuitively relative
within and across work settings. Risk implies a probability for injury, and the odds of an injury are a function of
the level of risk and worker exposure time. It is possible for workers at a site not to have injuries for a period of
time. The absence of injuries does not imply the absence of risk .Risk factors are defined as actions or
conditions that increase the likelihood of injury to the musculoskeletal system. Applied ergonomics literature
recognizes a small set of common physical risk factors across many occupations and work settings [11]. The
relationship between risk factor exposures and the level of musculoskeletal injury risk is not easily defined.
Although physical risk factors are important first-line risk factors, there are other plausible factors such as
organizational and psychosocial factors that may provoke a disorder or indirectly influence the effect of
physical risk factors. Three categories of risk factors are identified which are biomechanical exposures,
psychosocial stressors and individual risk factors. Biomechanical exposures include factors such as poorly
designed workplaces and biomechanical exposures such as repetitive motion, high forces and deviations from
neutral body alignments [12]. Psychosocial stressors at work include factors such as high-perceived workplaces
stress, low-perceived social support, low perceived job control, and time pressure [13].Individual factors
include gender (female), age, negative stress reactions-especially stomach reactions, and unsatisfactory leisure
time and/or additional domestic workload.Ergonomics hazards are workplace conditions and physical stressors
that cause a risk of injury or illness to the worker's musculoskeletal system (NIOSH, 1995). Of specific interest
7
are those hazards that pose a cumulative effect on the workers and which are called cumulative trauma disorders
(CTD) or work-related musculoskeletal disorders (WMSDs). They are also known as repetitive strain injury
(RSI) in Canada and the United Kingdom and cervicobrachial syndrome or occupational cervicobrachial
disorder in Japan and Sweden.”
-chandra, p. chandna& s. deswal, (2011)
“Ergonomics involves workstation set-up and design, body posture, prevention of computer related
injuries and more. Material Handling is the field concerned with solving the pragmatic problems involving the
movement, storage, control and protection of materials, goods and products throughout the processes of
cleaning, preparation, manufacturing, distribution, consumption and disposal of all related materials, goods and
their packaging. The objective of the project is to implement proper ergonomics and material handling in the
industry. Bossomaier, et al. The authors provide the readers with an accurate overview of the main scientific
approaches proposed (during the last two decades) by researchers and scientists working in this specific area. In
particular, two main scientific approaches have been identified. The first approach is based on the direct
analysis of the real workstations, while the second one uses computerized models to design workstations
ergonomically. Each scientific approach will be presented through a detailed description of the research works it
involves. The initial search identifies a huge number of articles which were reduced to about 60 studies based
on content and quality. Note that the research works description represents the core part of this literature review.
Mahatme, et al. (2014) provided detailed ergonomic analysis and workstation design for sheetmetal disc, teeth
cutting operation on a power press. Presently the operation under consideration is manual. The worker manually
picks the disc from the input bin and places it onto a press bed for teeth cutting and after completion, removes
the disc and places it into an output pin. For studying the ergonomic conditions of the worker, a detailed RULA
and REBA analysis of the work is carried out. A conceptual CAD model is developed for this purpose. The
simulation of the CAD model is done, which verifies its workability. The design of the CAD model is done. The
software used for RULA analysis and CAD model development and simulation is CATIA V5R19. For REBA
analysis REBA assessment worksheet is used. Wanave, et al. (2014) had shown that the evaluation of the
workstation to improve the productivity by reducing the back pain, shoulder injury, fatigue, etc. In
industrialized countries, upper limb work-related musculoskeletal disorders (ULWMSDs) are the most common
form of occupational diseases. It is shown that the suggested workstation improves working posture and results
in reduced postural stress on operators’ bodies and, consequently, reduce the prevalence of MSDs symptoms.
Charnes, et al. (1996) provide a review on awareness of Virtual Reality with respect to simulation. A brief
tutorial will be presented to clarify the terminology employed in the field. Examples of applications in a range
of fields will be given, using Virtual Reality software combined with a variety of simulation engines. Virtual
Reality devices will be available, affording attendees to experience different modes of involvement with the
simulated environment. Dufort, et al. (1999) studied that the development and reliability evaluations of a
checklist for measuring the state of housekeeping in the industry. This study involves the development and
reliability evaluations of a checklist for measuring the state of housekeeping in the industry. The instrument was
tested in fifty nine companies in the transportation equipment and machinery manufacturing sector in Quebec,
Canada each employing between twenty and sixty workers. The checklist, walk through procedure usually
required under thirty minutes. Choi, et al. (2002) had discussed the initial efforts to implement simulation
modeling as a visual management and analysis tool at an automotive foundry plant manufacturing engine block.
The foundry process was modeled using Pro Model to identify bottlenecks and evaluate machine performance,
cycle times and production data (total parts, rejects, throughput, products/HR) essential for efficient production
control. Results from the current system identified an assembly machine work area as the bottleneck (although
utilization was greater than 95% for two assembly machines) resulting in high work-in-process (WIP) inventory
level, low resource and machine utilization. Based on these results, optimum numbers were identified through
the use of scenarios by varying the number of assembly machines and processing time of each machine. Shinde,
et al. (2012) study was conducted on assembly workstation of the welding shop. Ergonomic study of this
assembly workstation was done by using motion study. Observations were made by studying each element of
motion film recorded by the video recorder. The results from this study shown that there is a need to modify
8
workstation layout according to ergonomic principles. Wilson, et al. (2012) covered a review of the evidence
for the physical and cognitive factors that characterize an ageing workforce in manufacturing. From an
ergonomics and human factors (E/HF) perspective, characteristics of manufacturing tasks and the effects of
ageing provide an insight into how the industry will have to adapt to support the user needs of the older worker
in the future. The approach taken is drawn from an Ilmarinen’s framework of age, experience, and work
performance, from which specific E/HF issues are explored. Fang, et al. (2007) investigated the risk factors of
WMSDs for hairdressers by identifying the body regions associated with significant discomfort. Twelve
professional Taiwanese hairdressers were invited to join this pilot study in Taiwan using a hairdresseroriented
musculoskeletal questionnaire to develop the study. The results from the study show that 91.7% of subjects
reported shoulder discomfort as the most frequent problem followed by discomfort in the lower back (83.3%)
and in the neck region (75%). The Objective of the study reveals that the effects of ageing could increase
discomfort levels in the lower back and lower leg. Trentin, et al. (2012) had shown that thermography as a
means to make an ergonomic evaluation of a job in metal casting, an area that involves activities that are energy
sapping wearisome and uncomfortable for workers. Use was made of the method of macroergonomic analysis
of work proposed by Guimarães (1998), in a medium sized industry, in the sectors of manual molding and
finishing. 27 workers were evaluated. Based on this method and statistical analysis, the finishing sector was
identified as the most critical one, in which thermograms were collected during the work activity of a volunteer.
The results indicate that the analysis of thermograms assists in the evaluation of work activities, as the physical
exertion expended is quantified.”
-Arijit Sengupta New Jersey Institute of Technology | NJIT · Department of Engineering Technology
“Global competition has initiated aggressive industrial and economic progress. This trend demands
higher productivity levels in manufacturing sector. Workers in this sector are set with high output targets in
developing countries like India. Not only intense competition in businesses lead to severe physical and mental
stresses on workers but also human factors and occupational health related issues in these workplaces have
become complicated and pushing these issues to a backstage (Saiyed and Tiwari, 2004). This is true in all type
industries, demanding the attention of ergonomic interventions, in current scenario. The following contributions
from various fields covering agriculture, engineering, medical, etc. bring forward the importance of ergonomic
studies. Nag et al (1992) have examined the work stresses of 107 women who were engaged in sewing machine
operation in small garment manufacturing units. The study identifies that about 68% of the women have
complain of back pain. Among them, 35% have reported a persistent low back pain. Piercing of the needle
through the fingers particularly the right forefingers is another common sewing work accident reported in this
study. Burdoff and Duuren (1993) have conducted a survey among operators in the woodworking industry to
study the effect of machine 10 characteristics on exposure to mechanical load. Work postures and external load
have been analyzed with the help of Ovako working posture analysis system. The analysis have indicated the
beneficial effects achieved by various ergonomic improvements. Bao et al (1996) have rationalized the system
in an assembly plant with deliberate ergonomic implications and evaluated the impact of the rationalization on
the physical work load of operators. The work load has been assessed before and after the changes using expert
observations, company records and direct technical measurements. The results have showed that the physical
work load on operators after the change has reduced. Brause and Pietruschka (1998) have identified the
problems in a rubber industry and proposed an adaptive solution for process control.”
- M. Dufort, C. I. Rivard, (1999)
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3. METHODOLOGY:
Workplace design refers to the process of designing and organizing a workplace to optimize worker
performance and safety. It is an important health and safety issue
for workers in both high-risk environments (such as construction sites) and low-risk
Workplaces (such as offices). Workplace design principles involve efforts to optimize the safety and health
conditions of regular work activities Workplace measures such as ergonomic seating and temperature control,
as well as efforts to protect workers in high-risk industries Through measures like designing safe navigation
routes through construction sites. Some workplaces use detailed aesthetic designs to reduce worker stress.
Industrial design principles can involve a variety of different safety-focused practices, such as designing a work
floor so that workers have enough space to move around dangerous equipment or by ensuring that safety
equipment is easily accessible.
WORKPLACE STRATEGIES:
“Performance = Ability x Motivation x Opportunity”
Ten workplace design considerations:
Ten fundamental design elements can positively impact the workplace environment and support the work being
done,
1. Thermal Comfort and Temperature
2. Access to Nature, Views and Daylight
3. Sensory Change and Variability
4. Color
5. Noise Control
6. Crowding
7. Human Factors and Ergonomics
8. Indoor Air Quality
9. Choice
10. Employee Engagement
There are numerous factors that come into consideration while considering the workstation deign. Here we have
taken into account some of the factors which plays an important part in workstation design. To analyze those
factors we have done some experiments in our garment construction laboratory and took observations as per the
requirement.
10
LIGHT
 Natural Light:
Open spaces at the perimeter of the floor allow light to penetrate deeper into the floor plate, providing access to
daylight for interior spaces. It is a must to maintain the light exposure in a optimum way as too much and too
little of it is always a hinderance. This was well tested and feedbacks are taken while recording the set of
activities performed while working. The various feedbacks and experimentations are,
Is able to sew without any hinderance due to optimum light exposure. This lessens the strain to the eyes and
also provides ease of operation.
 Dim Light
When working in a dim light or not sufficient lighting, eye sight gets disturbed and it causes difficulties in doing
a job. This later on leads to decrease in productivity. Thus, enforcing the need for optimum lighting.
The observation was taken for three workers for a time period of 60 minutes to check the productivity of the
workers with the condition of sufficient light and with the condition of insufficient light.
S.No Sufficient light(no of workers) Work done Insufficient light(no of workers) Work done
1. Worker 1 60 mins Worker 1 15 mins
2. Worker 2 60 mins Worker 2 12 mins
3. Worker 3 60 mins Worker 3 18 mins
From the observed data we can find that sufficient light is very much required for the students to work in the
sewing machine as it does not put stress on their eyes and they work in ease, rather than insufficient with leads
to headache and dizziness.
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NOISE
Phone rooms dispersed throughout the workplace support the open environment and provide opportunities for
private phone conversations or heads-down work.High traffic areas by large conference spaces, breakout space,
and reception, are located at the entrance to the floor, consolidating activity and noise to minimize disruption to
individual workplaces. Separating open workstations with enclosed spaces helps to maintain noise. Too many
open workstations create a feeling of overcrowding and can be too noisy.
The observation was taken for three workers for a time period of 30 minutes to check the productivity and
comfort zone of the workers with the condition of opening the lab door and with the condition of closing the
door.
S.No Door open (no of workers) Work done Door closed (no of workers) Work done
1. Worker 1 Incomplete Worker 1 Complete
2. Worker 2 Incomplete Worker 2 Complete
3. Worker 3 Incomplete Worker 3 Complete
From the observed data we can find that students need an environment where there is no noise or less noise that
does not drive their concentration, rather than extreme noise where putting concentration and completion of
work becomes difficult.
SEATING ARRANGEMENT:
The seating arrangement of the workers is very much important as it directly affects the productivity of the
workers. We tried analyzing the seating facilities with few chairs and the outcome is as follows.
 Lab Chair
Extra tall that would cause disgaze, also no backrest, hence causes severe discomfort and makes the worker
quickly tired.
“I couldn’t work with it. My leg barely supported the pedal and I couldn’t balance myself as comfortably as
needed. My back started paining within few minutes. I don’t find this comfortable at all”.
12
 Rolling Chair:
Keeps on moving, thus making it difficult to maintain a posture and working on it.
“It wasn’t easy to sew sitting on a rolling chair. I have to pause every second minute to adjust the posture and to
keep the chair in position.”
 Normal Chair:
Easy to work, posture friendly, prevents back ache.
“The chair is quite comfortable. It was convenient and I would prefer using it in comparison to the other
chairs.I couldn’t work with it. My leg barely supported the pedal and I couldn’t balance myself as comfortably
as needed. My back started to pain within few minutes. I don’t find this comfortable at all.”
The observation was taken for three workers for a time period of 30 minutes with a condition of seating on
tool(lab chair), on rolling chair, on normal plastic chair.
S.No Tool(no.of
workers)
Work done Rolling Chair(no.
of workers)
Work done Normal
Chair(no. of
workers)
Work done
1. Worker 1 6 mins Worker 1 10 mins Worker 1 18 mins
2. Worker 2 4 mins Worker 2 13 mins Worker 2 20 mins
3. Worker 3 5 mins Worker 3 10 mins Worker 3 17 mins
From the observed data we can find that the students were not comfortable to work while seating on tool and
rolling chair and they couldn’t sit for a longer time and stitch in comparison to the normal plastic chair. But
while seating on plastic chair and working their back starting paining after some time. Thus the students were
comfortable seating on metal chair that is put in the lab and find it quite comfortable for their back to rest.
13
THE LAYOUT:
By observation among the students we find that the U-shaped layout will be more comfortable.
The next important thing after ergonomics that plays an important role in maintaining the ambience and
improving the productivity in the company is its layout and its way of arrangement.
U-Shaped layout:
The U-line is actually quite famous in lean manufacturing. Often it is praised as the best possible line layout.
This U-shaped line is indeed quite nifty, but it is not a universal solution for anything.The U-line is used mostly
for manual manufacturing lines. A U-line is less ideal for fully or mostly automated lines. The main benefit
exists if multiple operators are within the “U” of the line. All the operators are within the “U,” while the
material is supplied from outside of the “U.” This of course requires devices and tools to bring the material
across the line from the outside to the inside. Slides and chutes are often used to bring material over the line,
and roller conveyors for material from underneath of the line. Often, a separate operator (usually called a
“point-of-use provider”) is in charge of refilling these devices from the outside using material provided by
logistics. Overall, refilling material in an U-line is not as easy as with an I-line, but often other benefits make
this effort worthwhile.
ADVANTAGES:
The ability of workers to tend multiple processes within the line. Since not only the adjacent workstations but
also the workstation “on the other side” are close by, the worker can manage multiple work stations. Therefore
this type of line is well suited for multi-machine handling.An additional benefit is that a worker can tend to both
the beginning and the end of a line. If the line has a breakdown or problem, the worker can tend to the section in
trouble and can temporarily neglect the other end of the line. Overall, breakdowns and other problems may be
fixed faster than in other lines.
In this line, the operator loads the machines and starts the process before moving to the next machine(s). The
machine works independently and ejects the part afterward before the worker loops back to the machine.
Automating ejection from a machine is much easier than placing a part in a machine.
Since an operator can tend to multiple machines without excessive walking distances, this type of line is well
suited to be scaled up and down by adding or removing workers.
If demand is very high, you put a worker at every workstation and the total output goes up.
If demand is lower, you reduce more and more workers from the line, until at the end only a single worker
handles all the processes, producing only a few parts. Of course you would have to ensure that the machines are
fast enough, and that the workers in the different settings all have similar workloads to avoid waiting times of
operators.
14
4.RESULTS
A well organized work station minimizes the material handling and also improves efficiency and reduces the
fatigue of workers. Thus after analyzing the different factors that are related to the work station design, we have
found that the U shaped layout works well in terms of designing the work station as it effectively increases the
productivity and the work continues in a smooth manner along with the layout the different conditions are also
considered while making the work station. There should be possible comfortable conditions so that the working
environment becomes convenient for the workers to work and thereby grow the productivity of the industry.
The derivations include:
 Comfortable seating position
 Proper lighting
 Proper setup of the work table
 Good ventilation
 Appropriate foot rest
 Noise management
15
5. CONCLUSION
The study thereby brought to light many issues which were effecting the workers health as well as leading to
many health issues. It is also found that ergonomics awareness is very less in the industry and thus we need to
be aware of the fact so that it does not cause any obstacle in terms of working activities of the workers. The
information that is gained after a lot of research on the work station design focused our attention on areas where
working conditions can be improved. The ample scope of improvement involves the work station design,
machine layout, working conditions that comes with the objective of providing maximum comfort to workers to
enhance their health and well being.
16
6. REFERANCES:

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Work Station Designing for Apparel Industry

  • 1. 1 “WORK STATION DESIGNING” PROJECT REPORT Submitted for PBL in Industrial Engineering(FST3003) By R PRIYANGA(16BFT1004); N SARANYA(16BFT1006); RITUPARNA MODAK (16BFT1012); P AMIRTHA VARSHINI(16BFT1015). Slot:C1 Name of faculty: Ms. N Gayathri VIT FASHION INSTITUTE OF TECHNOLOGY March, 2019
  • 2. 2 CERTIFICATE This is to certify that the Project work entitled “WORK STATION DESIGNING” submitted byR.Priyanga(16BFT1004),N.Saranya(16BFT1006), Rituparna Modak (16BFT1012), P.Amirthavarshini (16BFT1015)to VIT University, Chennai Campus, in partial fulfillment of the requirement for the award of the degree B.Tech in Fashion Technology undertaken by her under my supervision for the subjectIndustrial Engineering(FST3003).The project completed the requirements as per the regulations of this Institute and inmy opinionthe necessary standards for submission. Itis a record of bonafide work done under my supervision. The contents of this Project work have not been submitted for any other PBL course. Signature of Faculty: Prof. N Gayathri
  • 3. 3 ACKNOWLEDGEMENT The success and the final outcome of this project required of guidance and assistance from many people and we are extremely fortunate to have got this all along the completion of our project work. Whatever we have done is only due to such guidance and assistance and we would not forget to thank them. I respect and thank Prof. N Gayathri for giving us an opportunity to do this project and providing us all the support and guidance which made us complete the project on time. We are extremely grateful to them for providing such nice support and guidance. We would also like to thank VIT University, Chennai for giving us an opportunity to do this project. This project cannot be completed without the effort and cooperation of our group members. Last but not the least we would like to thank our friends for helping us in completion of the project within the limited time frame. Place: Chennai R PRIYANGA(16BFT1004); Date: 3/04/2019 N SARANYA(16BFT1006); RITUPARNA MODAK (16BFT1012); P AMIRTHA VARSHINI(16BFT1015).
  • 4. 4 ABSTRACT India is agreed to carve a name for it as a hub for export oriented garment manufacturing centre globally. Many researches prove that the garment industry is the largest manufacturing sector in India. Reports also state that the workers in the apparel hub go through a lot of enck pain, lower back pain etc. Thus a good ergonomics is very important for the workers to experience so that they can they can work effectively and make the apparel hub as the leading hub in the world. Through literature review done based on the works carried out majorly in India, it is found that the poorly designed workstation contribute to give trauma disorders which involves musculoskeletal disorders of the upper limbs, shoulders and neck. The main aim of this paper is to reflect upon the work station designs which directly relates to the good ergonomics so that the workers can work efficiently. Good ergonomics makes it very better for the workers to work very efficiently which again relates to numerous factors that should be improved so that the efficiency can be increased. To recognize ergonomics risk factors in the work place is an essential step in correcting the hazards and improving worker protection. For the worker protection factors like proper layout of the work station, proper arrangement of the table and chair, arrangement of the machines etc should be considered while effectively designing the work station.
  • 5. 5 1. INTRODUCTION: Work Station is a place where operators perform their job. It is the place where operators find their equipments to finish their task. Thus the work of the operators completely depends upon the work station that is the facility and the environment that the operator has to work for. A well designed work station is very important for the productivity of the work that is done by the operators. The work station should be designed according to the needs of the individual workers depending upon the type of workers and the task that they do. The work station should be designed keeping in mind the machineries that are used and the machines that are continuously operated by the workers. A well-organised work station should be well-lit, free from the noise, chemical hazards. That provides comfort zone for the workers to work, involves minimal material handling and thereby reduces fatigue and increases the efficiency of the workers. To design the work station several factors are considered. The layout is the major factor of work station design which involves the design of the arrangement of the workstation like the placement of the machineries, chairs, tables, support for the body parts while working in the machines, equipments arrangements ets. There are different types of layout used in apparel industry such as process layout, line layout, combination layout, u-shaped layout etc. According to the layout chosen the required arrangements can be done, so that the operators can frequently use the tools in the usual work area and can reach without stretching. The tools such as nippers and scissors that are used frequently can be attached to the machine. The other small items such as buttons, hooks etc can be kept in a separate place with a label on each section for clear identification. The sitting position of the operators is a major factor of lower back pain, nekc pain etc that can be improved by a good work station design by providing a backrest and a comfortable foot rest so that workers get it easy to work on the machines. There should be adequate leg room as well so that workers can change their leg position every time they want. To consider the height of the work benches, it should be designed in such a way so that workers can keep their arms low and elbows close to the body. Appropriate lighting is very essential for the workers to work in the sewing machine. Lighting should be bright to an extent so that it allows an easy and clear visibility for the workers rather than glaring at the workers eyes. Ventilation is an important part so that there does not occur suffocation when the workers are working. Along with the light bulbs that are used there should be provision for the natural light to pass through as this gives comfort to the eyes during the early morning hours. Waste clearance provision should be there in the apparel industry due to high accumulation of sewing wastes when inhaled causes lungs and breathing problems. Features in the garment industry can be improved by communication, involvement among the employees in decision making, education and training of employees and management on prevention strategies and the ergonomics conditions at the plant. The clothing industry is generally seen as a safe place to work when it is taken in comparison to other industries. Thus the factors that can relate to reduce the injury rates includes empowerment of the workforce, higher seniority of the workforce, safety protocols, better house keeping and active role of top management so that the designed work station efficiently functions to increase and continue the productivity of the industry.
  • 6. 6 2.LITERARURE REVIEW: “The paper proposes a literature review on workplaces ergonomic effective design in the manufacturing systems and industrial plants sector. The main objective is to provide the reader with an accurate overview on the main scientific approaches proposed (during the last decades) by researchers and scientists working in this specific area. The paper passes through the description of several research works as they run through the literature. The initial search identifies a huge number of articles which were reduced to about 50 studies based on content and quality. The descriptive analysis of the literature reveals heterogeneity in the content of the scientific approaches due to the different principles, methods and tools applied for improving the interaction between humans and their working environment. Workstation partitions are used in open plan offices for many reasons and come in a wide variety of materials, types, and shapes. The position, height, and orientation of partitions affect the amount and distribution of daylight entering a building as well as all forms of thermal transfer through windows. However, these potential impacts cannot be determined if not adequately addressed in guidelines and standards, and could mislead decision-making during design stages and hamper the refinement of office furniture manufacturing. This study outlines exploring partition design, open offices, lighting and daylighting quality, and codes and standards in detail which helps draw attention to the possible partition layouts that are both effective and economical to overcome glare and visually uncomfortable conditions in open plan offices. More widespread application of daylight-based partition design in open plan offices could result in a better understanding of their performances, as well as improvements in their overall efficiency.” -shikdar, (2004), “Workplaces traditionally have been designed to move products or support machines efficiently. Since people have always seemed so adaptable, how they fit into the workplace has received less attention. The increasing number of injuries caused by repetitive motion, excessive force and awkward postures, ergonomics has become a critical factor in workplace safety. According to Hagberg et al. [9], ergonomics and human factors are often used interchangeably in workplaces. Both describe the interaction between the worker and the job demands. The difference between them is ergonomics focuses on how work affects workers, and human factors emphasize designs that reduce the potential for human error. While Bongers et al [10] stress that by addressing traditional and environmental risk factors, it can keep workers injury free. Risk and risk factors are common concepts used in safety and applied ergonomics literature. Risk includes a component of how likely or what the probability of an event is and the seriousness of the consequence or what the severity is if something does occur. Risk is often defined on how many injuries or accidents resulted for a given exposure. At the extremes, injury risk can be viewed as very low probability but extremely high consequence (e.g.: multiple fatalities) or higher probability but less severe consequence (e.g.: a worker slipping and tripping. Risk is also intuitively relative within and across work settings. Risk implies a probability for injury, and the odds of an injury are a function of the level of risk and worker exposure time. It is possible for workers at a site not to have injuries for a period of time. The absence of injuries does not imply the absence of risk .Risk factors are defined as actions or conditions that increase the likelihood of injury to the musculoskeletal system. Applied ergonomics literature recognizes a small set of common physical risk factors across many occupations and work settings [11]. The relationship between risk factor exposures and the level of musculoskeletal injury risk is not easily defined. Although physical risk factors are important first-line risk factors, there are other plausible factors such as organizational and psychosocial factors that may provoke a disorder or indirectly influence the effect of physical risk factors. Three categories of risk factors are identified which are biomechanical exposures, psychosocial stressors and individual risk factors. Biomechanical exposures include factors such as poorly designed workplaces and biomechanical exposures such as repetitive motion, high forces and deviations from neutral body alignments [12]. Psychosocial stressors at work include factors such as high-perceived workplaces stress, low-perceived social support, low perceived job control, and time pressure [13].Individual factors include gender (female), age, negative stress reactions-especially stomach reactions, and unsatisfactory leisure time and/or additional domestic workload.Ergonomics hazards are workplace conditions and physical stressors that cause a risk of injury or illness to the worker's musculoskeletal system (NIOSH, 1995). Of specific interest
  • 7. 7 are those hazards that pose a cumulative effect on the workers and which are called cumulative trauma disorders (CTD) or work-related musculoskeletal disorders (WMSDs). They are also known as repetitive strain injury (RSI) in Canada and the United Kingdom and cervicobrachial syndrome or occupational cervicobrachial disorder in Japan and Sweden.” -chandra, p. chandna& s. deswal, (2011) “Ergonomics involves workstation set-up and design, body posture, prevention of computer related injuries and more. Material Handling is the field concerned with solving the pragmatic problems involving the movement, storage, control and protection of materials, goods and products throughout the processes of cleaning, preparation, manufacturing, distribution, consumption and disposal of all related materials, goods and their packaging. The objective of the project is to implement proper ergonomics and material handling in the industry. Bossomaier, et al. The authors provide the readers with an accurate overview of the main scientific approaches proposed (during the last two decades) by researchers and scientists working in this specific area. In particular, two main scientific approaches have been identified. The first approach is based on the direct analysis of the real workstations, while the second one uses computerized models to design workstations ergonomically. Each scientific approach will be presented through a detailed description of the research works it involves. The initial search identifies a huge number of articles which were reduced to about 60 studies based on content and quality. Note that the research works description represents the core part of this literature review. Mahatme, et al. (2014) provided detailed ergonomic analysis and workstation design for sheetmetal disc, teeth cutting operation on a power press. Presently the operation under consideration is manual. The worker manually picks the disc from the input bin and places it onto a press bed for teeth cutting and after completion, removes the disc and places it into an output pin. For studying the ergonomic conditions of the worker, a detailed RULA and REBA analysis of the work is carried out. A conceptual CAD model is developed for this purpose. The simulation of the CAD model is done, which verifies its workability. The design of the CAD model is done. The software used for RULA analysis and CAD model development and simulation is CATIA V5R19. For REBA analysis REBA assessment worksheet is used. Wanave, et al. (2014) had shown that the evaluation of the workstation to improve the productivity by reducing the back pain, shoulder injury, fatigue, etc. In industrialized countries, upper limb work-related musculoskeletal disorders (ULWMSDs) are the most common form of occupational diseases. It is shown that the suggested workstation improves working posture and results in reduced postural stress on operators’ bodies and, consequently, reduce the prevalence of MSDs symptoms. Charnes, et al. (1996) provide a review on awareness of Virtual Reality with respect to simulation. A brief tutorial will be presented to clarify the terminology employed in the field. Examples of applications in a range of fields will be given, using Virtual Reality software combined with a variety of simulation engines. Virtual Reality devices will be available, affording attendees to experience different modes of involvement with the simulated environment. Dufort, et al. (1999) studied that the development and reliability evaluations of a checklist for measuring the state of housekeeping in the industry. This study involves the development and reliability evaluations of a checklist for measuring the state of housekeeping in the industry. The instrument was tested in fifty nine companies in the transportation equipment and machinery manufacturing sector in Quebec, Canada each employing between twenty and sixty workers. The checklist, walk through procedure usually required under thirty minutes. Choi, et al. (2002) had discussed the initial efforts to implement simulation modeling as a visual management and analysis tool at an automotive foundry plant manufacturing engine block. The foundry process was modeled using Pro Model to identify bottlenecks and evaluate machine performance, cycle times and production data (total parts, rejects, throughput, products/HR) essential for efficient production control. Results from the current system identified an assembly machine work area as the bottleneck (although utilization was greater than 95% for two assembly machines) resulting in high work-in-process (WIP) inventory level, low resource and machine utilization. Based on these results, optimum numbers were identified through the use of scenarios by varying the number of assembly machines and processing time of each machine. Shinde, et al. (2012) study was conducted on assembly workstation of the welding shop. Ergonomic study of this assembly workstation was done by using motion study. Observations were made by studying each element of motion film recorded by the video recorder. The results from this study shown that there is a need to modify
  • 8. 8 workstation layout according to ergonomic principles. Wilson, et al. (2012) covered a review of the evidence for the physical and cognitive factors that characterize an ageing workforce in manufacturing. From an ergonomics and human factors (E/HF) perspective, characteristics of manufacturing tasks and the effects of ageing provide an insight into how the industry will have to adapt to support the user needs of the older worker in the future. The approach taken is drawn from an Ilmarinen’s framework of age, experience, and work performance, from which specific E/HF issues are explored. Fang, et al. (2007) investigated the risk factors of WMSDs for hairdressers by identifying the body regions associated with significant discomfort. Twelve professional Taiwanese hairdressers were invited to join this pilot study in Taiwan using a hairdresseroriented musculoskeletal questionnaire to develop the study. The results from the study show that 91.7% of subjects reported shoulder discomfort as the most frequent problem followed by discomfort in the lower back (83.3%) and in the neck region (75%). The Objective of the study reveals that the effects of ageing could increase discomfort levels in the lower back and lower leg. Trentin, et al. (2012) had shown that thermography as a means to make an ergonomic evaluation of a job in metal casting, an area that involves activities that are energy sapping wearisome and uncomfortable for workers. Use was made of the method of macroergonomic analysis of work proposed by Guimarães (1998), in a medium sized industry, in the sectors of manual molding and finishing. 27 workers were evaluated. Based on this method and statistical analysis, the finishing sector was identified as the most critical one, in which thermograms were collected during the work activity of a volunteer. The results indicate that the analysis of thermograms assists in the evaluation of work activities, as the physical exertion expended is quantified.” -Arijit Sengupta New Jersey Institute of Technology | NJIT · Department of Engineering Technology “Global competition has initiated aggressive industrial and economic progress. This trend demands higher productivity levels in manufacturing sector. Workers in this sector are set with high output targets in developing countries like India. Not only intense competition in businesses lead to severe physical and mental stresses on workers but also human factors and occupational health related issues in these workplaces have become complicated and pushing these issues to a backstage (Saiyed and Tiwari, 2004). This is true in all type industries, demanding the attention of ergonomic interventions, in current scenario. The following contributions from various fields covering agriculture, engineering, medical, etc. bring forward the importance of ergonomic studies. Nag et al (1992) have examined the work stresses of 107 women who were engaged in sewing machine operation in small garment manufacturing units. The study identifies that about 68% of the women have complain of back pain. Among them, 35% have reported a persistent low back pain. Piercing of the needle through the fingers particularly the right forefingers is another common sewing work accident reported in this study. Burdoff and Duuren (1993) have conducted a survey among operators in the woodworking industry to study the effect of machine 10 characteristics on exposure to mechanical load. Work postures and external load have been analyzed with the help of Ovako working posture analysis system. The analysis have indicated the beneficial effects achieved by various ergonomic improvements. Bao et al (1996) have rationalized the system in an assembly plant with deliberate ergonomic implications and evaluated the impact of the rationalization on the physical work load of operators. The work load has been assessed before and after the changes using expert observations, company records and direct technical measurements. The results have showed that the physical work load on operators after the change has reduced. Brause and Pietruschka (1998) have identified the problems in a rubber industry and proposed an adaptive solution for process control.” - M. Dufort, C. I. Rivard, (1999)
  • 9. 9 3. METHODOLOGY: Workplace design refers to the process of designing and organizing a workplace to optimize worker performance and safety. It is an important health and safety issue for workers in both high-risk environments (such as construction sites) and low-risk Workplaces (such as offices). Workplace design principles involve efforts to optimize the safety and health conditions of regular work activities Workplace measures such as ergonomic seating and temperature control, as well as efforts to protect workers in high-risk industries Through measures like designing safe navigation routes through construction sites. Some workplaces use detailed aesthetic designs to reduce worker stress. Industrial design principles can involve a variety of different safety-focused practices, such as designing a work floor so that workers have enough space to move around dangerous equipment or by ensuring that safety equipment is easily accessible. WORKPLACE STRATEGIES: “Performance = Ability x Motivation x Opportunity” Ten workplace design considerations: Ten fundamental design elements can positively impact the workplace environment and support the work being done, 1. Thermal Comfort and Temperature 2. Access to Nature, Views and Daylight 3. Sensory Change and Variability 4. Color 5. Noise Control 6. Crowding 7. Human Factors and Ergonomics 8. Indoor Air Quality 9. Choice 10. Employee Engagement There are numerous factors that come into consideration while considering the workstation deign. Here we have taken into account some of the factors which plays an important part in workstation design. To analyze those factors we have done some experiments in our garment construction laboratory and took observations as per the requirement.
  • 10. 10 LIGHT  Natural Light: Open spaces at the perimeter of the floor allow light to penetrate deeper into the floor plate, providing access to daylight for interior spaces. It is a must to maintain the light exposure in a optimum way as too much and too little of it is always a hinderance. This was well tested and feedbacks are taken while recording the set of activities performed while working. The various feedbacks and experimentations are, Is able to sew without any hinderance due to optimum light exposure. This lessens the strain to the eyes and also provides ease of operation.  Dim Light When working in a dim light or not sufficient lighting, eye sight gets disturbed and it causes difficulties in doing a job. This later on leads to decrease in productivity. Thus, enforcing the need for optimum lighting. The observation was taken for three workers for a time period of 60 minutes to check the productivity of the workers with the condition of sufficient light and with the condition of insufficient light. S.No Sufficient light(no of workers) Work done Insufficient light(no of workers) Work done 1. Worker 1 60 mins Worker 1 15 mins 2. Worker 2 60 mins Worker 2 12 mins 3. Worker 3 60 mins Worker 3 18 mins From the observed data we can find that sufficient light is very much required for the students to work in the sewing machine as it does not put stress on their eyes and they work in ease, rather than insufficient with leads to headache and dizziness.
  • 11. 11 NOISE Phone rooms dispersed throughout the workplace support the open environment and provide opportunities for private phone conversations or heads-down work.High traffic areas by large conference spaces, breakout space, and reception, are located at the entrance to the floor, consolidating activity and noise to minimize disruption to individual workplaces. Separating open workstations with enclosed spaces helps to maintain noise. Too many open workstations create a feeling of overcrowding and can be too noisy. The observation was taken for three workers for a time period of 30 minutes to check the productivity and comfort zone of the workers with the condition of opening the lab door and with the condition of closing the door. S.No Door open (no of workers) Work done Door closed (no of workers) Work done 1. Worker 1 Incomplete Worker 1 Complete 2. Worker 2 Incomplete Worker 2 Complete 3. Worker 3 Incomplete Worker 3 Complete From the observed data we can find that students need an environment where there is no noise or less noise that does not drive their concentration, rather than extreme noise where putting concentration and completion of work becomes difficult. SEATING ARRANGEMENT: The seating arrangement of the workers is very much important as it directly affects the productivity of the workers. We tried analyzing the seating facilities with few chairs and the outcome is as follows.  Lab Chair Extra tall that would cause disgaze, also no backrest, hence causes severe discomfort and makes the worker quickly tired. “I couldn’t work with it. My leg barely supported the pedal and I couldn’t balance myself as comfortably as needed. My back started paining within few minutes. I don’t find this comfortable at all”.
  • 12. 12  Rolling Chair: Keeps on moving, thus making it difficult to maintain a posture and working on it. “It wasn’t easy to sew sitting on a rolling chair. I have to pause every second minute to adjust the posture and to keep the chair in position.”  Normal Chair: Easy to work, posture friendly, prevents back ache. “The chair is quite comfortable. It was convenient and I would prefer using it in comparison to the other chairs.I couldn’t work with it. My leg barely supported the pedal and I couldn’t balance myself as comfortably as needed. My back started to pain within few minutes. I don’t find this comfortable at all.” The observation was taken for three workers for a time period of 30 minutes with a condition of seating on tool(lab chair), on rolling chair, on normal plastic chair. S.No Tool(no.of workers) Work done Rolling Chair(no. of workers) Work done Normal Chair(no. of workers) Work done 1. Worker 1 6 mins Worker 1 10 mins Worker 1 18 mins 2. Worker 2 4 mins Worker 2 13 mins Worker 2 20 mins 3. Worker 3 5 mins Worker 3 10 mins Worker 3 17 mins From the observed data we can find that the students were not comfortable to work while seating on tool and rolling chair and they couldn’t sit for a longer time and stitch in comparison to the normal plastic chair. But while seating on plastic chair and working their back starting paining after some time. Thus the students were comfortable seating on metal chair that is put in the lab and find it quite comfortable for their back to rest.
  • 13. 13 THE LAYOUT: By observation among the students we find that the U-shaped layout will be more comfortable. The next important thing after ergonomics that plays an important role in maintaining the ambience and improving the productivity in the company is its layout and its way of arrangement. U-Shaped layout: The U-line is actually quite famous in lean manufacturing. Often it is praised as the best possible line layout. This U-shaped line is indeed quite nifty, but it is not a universal solution for anything.The U-line is used mostly for manual manufacturing lines. A U-line is less ideal for fully or mostly automated lines. The main benefit exists if multiple operators are within the “U” of the line. All the operators are within the “U,” while the material is supplied from outside of the “U.” This of course requires devices and tools to bring the material across the line from the outside to the inside. Slides and chutes are often used to bring material over the line, and roller conveyors for material from underneath of the line. Often, a separate operator (usually called a “point-of-use provider”) is in charge of refilling these devices from the outside using material provided by logistics. Overall, refilling material in an U-line is not as easy as with an I-line, but often other benefits make this effort worthwhile. ADVANTAGES: The ability of workers to tend multiple processes within the line. Since not only the adjacent workstations but also the workstation “on the other side” are close by, the worker can manage multiple work stations. Therefore this type of line is well suited for multi-machine handling.An additional benefit is that a worker can tend to both the beginning and the end of a line. If the line has a breakdown or problem, the worker can tend to the section in trouble and can temporarily neglect the other end of the line. Overall, breakdowns and other problems may be fixed faster than in other lines. In this line, the operator loads the machines and starts the process before moving to the next machine(s). The machine works independently and ejects the part afterward before the worker loops back to the machine. Automating ejection from a machine is much easier than placing a part in a machine. Since an operator can tend to multiple machines without excessive walking distances, this type of line is well suited to be scaled up and down by adding or removing workers. If demand is very high, you put a worker at every workstation and the total output goes up. If demand is lower, you reduce more and more workers from the line, until at the end only a single worker handles all the processes, producing only a few parts. Of course you would have to ensure that the machines are fast enough, and that the workers in the different settings all have similar workloads to avoid waiting times of operators.
  • 14. 14 4.RESULTS A well organized work station minimizes the material handling and also improves efficiency and reduces the fatigue of workers. Thus after analyzing the different factors that are related to the work station design, we have found that the U shaped layout works well in terms of designing the work station as it effectively increases the productivity and the work continues in a smooth manner along with the layout the different conditions are also considered while making the work station. There should be possible comfortable conditions so that the working environment becomes convenient for the workers to work and thereby grow the productivity of the industry. The derivations include:  Comfortable seating position  Proper lighting  Proper setup of the work table  Good ventilation  Appropriate foot rest  Noise management
  • 15. 15 5. CONCLUSION The study thereby brought to light many issues which were effecting the workers health as well as leading to many health issues. It is also found that ergonomics awareness is very less in the industry and thus we need to be aware of the fact so that it does not cause any obstacle in terms of working activities of the workers. The information that is gained after a lot of research on the work station design focused our attention on areas where working conditions can be improved. The ample scope of improvement involves the work station design, machine layout, working conditions that comes with the objective of providing maximum comfort to workers to enhance their health and well being.