SUBMITTED TO,

MS. ETTISHRI RAJPUT

ASSISTANT PROFESSOR

SUBMITTED BY,
Ruchita Koshti, Neha Shishodia

A Document on Ergonomic Analysis

for the betterment of A Handloom
Weaving Process
Subject: Ergonomics

National Institute of Fashion Technology, Gandhinagar

Ergonomics and workplace Engineering, (EWPE)

A Document on
Ergonomic Analysis for the betterment of
A Handloom Weaving Process

For the partial fulfilment of completion of assignment

Submitted To,
Ms. Ettishri Rajput
Assistant Professor,
Department of Fashion Technology

Submitted By,
Neha Shishodia
Ruchita Koshti
MFT, 3rd Semester

Table of Contents:

1. Aim...i
2. Methodology of Assignment work...i
3. Process of weaving through Observation.....i
4. Stick diagram of process with actual photographs. ii
5. Questionnaire for analysis..iii
6. Problems found which contributes to CTDiii
7. Analysis of process ergonomically..v
8. H, M and E interaction according to our selected workstation....v
9. Analyzing the process systematically for identifying contributing factorsvi
10. Improving Workplace...viii
11. Conclusionviii
12. Bibliography...ix

Aim: to select a workstation, analyse it ergonomically and provide suggestions

for the improvement.
Work Station: TD Lab Handloom

Methodology of Assignment Work

selection of workstation

understanding process

list of problems

analysis with ergonomic perspective

Possible solutions

Process of weaving through Observation

Beating using
reeds

passing the
shuttle through
shade

Adjusting the
wefts using
fingers

Adjusting the
lever

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Stick diagram of process with actual photographs

Step 1: beating the swatch using reed

Step 2: adjusting warp yarns using fingers.

Step 3: adjusting the shade changing lever.

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Step 4: passing the shuttle through shades.

Questionnaire for analysis

1.
2.
3.
4.
5.
6.
7.
8.
9.

Explain the working of loom

How is the working environment?
What are the working hours?
Is the work tedious?
List of tasks.
What is the frequency of tasks?
Difficulty level of each task.
Scores according to difficulty level.
Which body parts are mostly affected.

Problems found which contributes to CTD

1.
2.
3.
4.
5.
6.
7.
8.

Height of machine with reference to operator.

Rod used in take-off operation.
Pain in forearm and shoulder.
Strain in legs because of long working hours.
Neck pain for taller person.
Back pain for shorter person.
m/c set-up comes off from the table after some forceful beating.
Improper m/c part design causing injuries.

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Following are the pictures of some problems witnessed.

Figure 1: workstation
Height of workstation is not idle for all.
Figure 2: rod used in take-off operation.

Figure 3: stool used for short people Figure 4: wound on hand of operator.

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Analysis of process ergonomically

Inputs

Noise (by-product)

By Products
Rework if mistake
happens ( by-product)

Products
Energy
Lever
Adjustment
Shuttle
passing

Weaved pattern
(Swatch)

H M

Injuries (by-product)

Energy

By Products

Description of process:
The above image represents the human, machine and environment interaction.
The inputs are the energy, lever adjustment and shuttle passing according to our
workstation.
After processing through the human-machine interaction it gives weaved pattern
(i.e. fabric swatch) as the product and leads to energy conversion also from kinetic
to mechanical.
The by-products are injuries, noise and rework if mistake happens.

H, M and E interaction according to our selected workstation

1. H > E: Emission of heat, noise and carbon dioxide in the environment.
Effect: In bulk production proper ventilation required else it will lead to
suffocation and dizziness to the operators.
2. H > M: Continuous forces on lever and reed.
Push force on machine in backward direction.
Effect: unnecessary wastage of energy.
Movement upto level 5.
Size of force is more that tolerance if worked for longer hours.
More fatigue because of longer working hours.
Mental workload because they need to check pick breakage in every cycle and for
pattern design.
3. M > H: Machine makes noise while beating and adjusting lever.
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Effect: Pain in hand and shoulder because of the application of force.

Sensory feedback is more than tolerance level.
4. M > E: Noise pollution in bulk production.
5. E > H: Tedious in summer season as the temperature effect the psychology and mood of
the operator.
6. E > M: Dust accumulation and natural effects of environment on wood.

Analyzing the process systematically for identifying contributing factors.

Step 1: after selection of job, the job is divided into number of tasks. So that it
becomes easier to analyze the job.
Job Title
Weaving of pattern
The tasks of job are:
1. Process of Beating using reeds: affect at level 2
2. Adjusting weft using fingers: affect at level 0
3. Adjusting the lever: affect at level 4
4. Pass the shuttle through shades : use of level 2 of hands
Step 2: Each task of job is given score according to level of difficulty and frequency. based on
results of score prioritization of task for improvements can be made. Format for level of
difficulty and frequency is shown below.
How hard the task is?
Vary easy
Easy
Somewhat hard
Hard
Very Hard

Score
1
2
3
4
5

How often this task

done?
Seasonally
Occasionally
Frequency
Constantly
Extended hours

Score
1
2
3
4
5

Step 3: Based on scoring formats tasks are given scores.

Tasks
Process of Beating using reeds
Adjusting weft using fingers
Adjusting the lever
Pass the shuttle through shades.

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Score for How hard *

Score for how often
3
4
5
4
4
4
1
4

= Total score
for the task
12
20
16
4

Step 4: from score card prioritize the task and make ergonomics awareness checklist
Ergonomics Awareness Checklist
Job Title: weaving
Name of Student: Prerna
Name of Observer: Ruchita, Neha

Job Location: Textile Design Weaving Lab

Date: 5th September, 2016

Contributing Factors
Reason for CF
Task 1 : Process of beating using reeds
This task will affect level 2.
Repetition
Requirement of process cycle
Forceful exertion

Individual capability is less

Comments
Total Score: 12
Twice per cycle operation is
done- high frequency
As girl was doing the task her
force was less than required

Task 2: Adjusting weft using fingers

This task will affect at level 0.
Pressure Points
High pressure on fingers

Total Score: 20

Task 3: Adjusting the lever

This task will affect at level 4 if person goes to the side lever.
And will affect at level 5 if person is lifting up & down while
standing in its place
Awkward posture
Work place is hard to reach
Repetition
Twice per cycle
Forceful exertion
Lever is above the height and
heavy and needed to lift it
down

Total Score: 16

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While moving weft yarn

towards back operator was
using fingers

Improving Workplace
Type of Improvement
Engineering improvements

Details of improvement
Entire handloom can be fitted
on adjustable table.
i.e. scissor table
Stool can come with
adjustable heights

Improvement for tools/

handles

Rod used in take-off options

can be covered with rubber
grip at both the ends.
Reed handles can be given
grips.
Stopping mechanism should
be attached to table edges

Engineering improvement

Shade changing levers can be

made besides of student
instead of at one side of m/c

comments
This improvement will solve
the problem caused to
different height of people
This improvement will solve
the problem caused to
different height of people
Wound caused because of
metal rod can be avoided.
With grips pain caused in
palm will get reduced
With this improvement
machine will not move
forward and come off the
range of table and eliminate
the unnecessary
This improvement will reduce
the strain in leg as well as
student have to move towards
lever to lift up & down

Other Improvements
Micro Resting

Resting after every one hour

for 4-5 minutes will give time
to muscles for recovery.

Conclusion:

Overall manual weaving is a tiresome job. So advanced technology should be used.

All problems cannot be eliminated as they are necessary value added activity.
The suggestions if worked upon can provide ease in work which can increase the
productivity.
Current set up is not safe as it caused injuries.

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Bibliography
[1] Departments of Industrial Relations, OSHA, "Easy Ergonomics," in A Practical Approach for
Improving the Workplace, California, OSHA, Departments of Industrial Relations, 1999, pp. 1-89.
[2] R. S. Briddger, "Introduction to Ergonomics," London and New-York, Routledge, Taylor and Francis
Group, 2003, pp. 1-563.

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