Final Year Thesis Work (By H&L) - Word Print

Analyzing the impact of indoor physical work environment on workers performance
BAHIR DAR UNIVERSITY
INSTITUTE OF TECHNOLOGY
SCHOOL OF MECHANICAL AND INDUSTRIAL ENGINEERING
INDUSTRIAL ENGINEERING PROGRAM
TITLE: ANALYZING THE IMPACT OF INDOOR PHYSICAL WORK

ENVIRONMENT ON WORKERS PERFORMANCE
(A case study on Bahir Dar Textile Share Company)
By:
Habtamu Tesfaye
Lelisa Deja
A Thesis submitted to School of Mechanical and Industrial Engineering, in
partial fulfillment of the requirement for the degree of Bachelor Science in
Industrial Engineering
Advisor: Miss. Tirufat Dejene (Msc.)
June, 2013
BAHIR DAR UNIVERSITY

INSTITUTE OF TECHNOLOGY
SCHOOL OF MECHANICAL AND INDUSTRIAL ENGINEERING
INDUSTRIAL ENGINEERING PROGRAM
TITLE: ANALYZING THE IMPACT OF INDOOR PHYSICAL WORK

ENVIRONMENT ON WORKERS PERFORMANCE
(A Case study on Bahir Dar Textile Share Company)
Submitted by:
1. Habtamu Tesfaye __________ _______

2. Lelisa Deja ______________ ___________
Student (s) Signature Date
Approved by:
1. _________________________ ___________ ____________
Advisor Signature Date
2. _________________________ ____________ ____________
Undergraduate Project Evaluation Committee Signature Date
3. _________________________ ____________ _____________
School Director Signature Date
BDU, IOT, School of Mechanical and Industrial Engineering Page I

Declaration
We declare that the work which is being presented in this thesis entitled Analyzing the impact
of indoor physical work environment on workers performance is our original work, has not
been presented for a degree of any other university and all the resource of materials used for this
thesis have been duly acknowledged.
_______________ _________
Habtamu Tesfaye
___________ _________
Lelisa Deja Date
This is to certify that the above declaration made by the candidate is correct to the best of my
knowledge.
________________________ __________
Ms. Tirufat Dejene (Msc.) Date
(Advisor)
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ACKNOWLEDGEMENT
First of all we would like to thanks our God for his endless helps. Next to him we want to thanks
our advisor Miss. Tirufat Dejene for her advisory criticisms, as well as her encouragement while
doing this thesis. And also we want to express our sincerely appreciation for Amhara Regional
State Bureau of Labors and Social Affairs who makes the venture of this study worthwhile by
providing us with the equipments such as sound level meter, lux meter, and thermo meter for
measuring workplace sound level, illumination level and room temperature.
Special thanks go to Mr. Ayalew Asmamaw the technician at the Amhara Regional State Bureau
of Labors and Social Affairs for his help, patience and taking his time, for measuring noise level,
light illumination level and temperature of the weaving, spinning and finishing sections of Bahir
Dar Textile Company. Our gratitude goes to Mr. Tamirat Tesfaye for his indispensable help in
financial term and by giving us his own lap top while doing this thesis work.
We are also indebted /grateful to the all other peoples not listed above, but who had contributed
to the completion of this thesis.
Thanks!
BDU, IOT, School of Mechanical and Industrial Engineering Page III

TABLE OF CONTENTS
ACKNOWLEDGEMENT .......................................................................................................................... III
TABLE OF CONTENTS............................................................................................................................ IV
LIST OF TABLES ...................................................................................................................................... VI
LIST OF FIGURES ...................................................................................................................................VII
ABBREVIATIONS ................................................................................................................................. VIII
ABSTRACT................................................................................................................................................ IX
CHAPTER ONE: INTRODUCTION ........................................................................................................... 1
1.1 Background of the study ..................................................................................................................... 1
1.2 Objectives of the study........................................................................................................................ 2
1.3 Methodology ....................................................................................................................................... 2
1.4 Scope of the thesis and Limitation ...................................................................................................... 3
1.5 Significance ........................................................................................................................................ 4
1.6 Structure and content of the thesis ...................................................................................................... 4
CHAPTER TWO: LITERATURE REVIEW ............................................................................................... 6
2.1 Introduction......................................................................................................................................... 6
2.2 Work Environment ............................................................................................................................. 6
2.2.1. Lighting ....................................................................................................................................... 7
2.2.2. Noise ........................................................................................................................................... 9
2.2.3 Vibrations................................................................................................................................... 13
2.2.4 Temperature and Humidity ........................................................................................................ 13
2.2.5. Air Quality ................................................................................................................................ 14
2.2.6 Office furniture and Equipments................................................................................................ 17
CHAPTER THREE: PROBLEM STATEMENT AND JUSTIFICATION ............................................... 18
3.1 Background of the case company ..................................................................................................... 18
3.2 Statement of the problems ................................................................................................................ 18
3.2.1 Poor air quality........................................................................................................................... 19
3.2.2 Illumination level ....................................................................................................................... 20
3.2.3 Noise .......................................................................................................................................... 21
3.2.4 Hot temperature ......................................................................................................................... 21
3.2.5 Machine layout and work overload ............................................................................................ 22
CHAPTER FOUR: DATA COLLECTION AND ANALYSIS ................................................................. 23
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4.1 Introduction....................................................................................................................................... 23
4.2 Working hour .................................................................................................................................... 23
4.3 Sound level, illumination level and temperatures at the workplace of Bahir Dar textile Share
Company ................................................................................................................................................. 24
4.4 Demographic characteristics of the respondents............................................................................... 25
4.5 Level of respondents satisfaction with physical work environment ................................................ 26
4.6 Impact of indoor physical work environment on performance of employees................................... 29
4.6.1 Spinning department .................................................................................................................. 30
4.6.2 Weaving department .................................................................................................................. 31
4.6.3 Finishing department ................................................................................................................. 32
4.7 Result of the survey using checklist.................................................................................................. 33
4.8 Clinical data ...................................................................................................................................... 36
4.9 Discussions of findings ..................................................................................................................... 39
CHAPTER FIVE: PROPOSED SOLUTION TO THE PROBLEMS ........................................................ 40
5.1 Introduction....................................................................................................................................... 40
5.2 Methods of noise control .................................................................................................................. 40
5.2.1 Controlling at the source ............................................................................................................ 41
5.2.2 Controlling noise along the path between the source and the workers ...................................... 43
5.2.3 Controlling the noise at the worker ............................................................................................ 44
5.3 Methods of controlling Lighting illumination .................................................................................. 46
5.4 Methods of controlling heat stress .................................................................................................... 47
5.5 Methods for monitoring air quality ................................................................................................... 51
CHAPTER SIX: CONCLUSION AND RECOMMENDATION .............................................................. 52
6.1 Conclusions....................................................................................................................................... 52
6.2 Recommendations ............................................................................................................................. 53
REFERENCE.............................................................................................................................................. 54
APPENDIX-A: QUESTIONNAIRE FOR DATA COLLECTION ........................................................... 55
APPENDIX- B: CHECKLIST.................................................................................................................... 57
APPENDIX C: ............................................................................................................................................ 59
TORNADO INDUTRIAL VENTILATION SYSTEM INSTALLATION PROCEDURE ....................... 59
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LIST OF TABLES
Tables....page
Table 2.1: Recommended illumination level...8
Table 2.2: permissible noise exposures OSHA standards.10
Table: 2.3: classification of dust based on size..................15
Table: 2.4: Permissible Exposure Limits (PEL) for Cotton Dust for Different Work Areas....16
Table 4.1 Measured values of noise level, illumination level, and temperature at
Bahir Dar Textile Share Company.24
Table 4.2 Record of measured temperature in spinning, weaving, and finishing shop
of Cause Company.25
Table 4.3: Clinical data taken from the companys document..37
Table A1: Employee satisfaction with workplace physical environment .56
TableA2: Effect of work place elements on employees performance regarding productivity.57
Table B1: An Ergonomics Checklist for Enhancing Comfort, Health and
Performance in a weaving, spinning and finishing shop of the case company..58
TableC1: Tornado roof ventilator installation procedure......59
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LIST OF FIGURES
Fig.1: Organization of the thesis content.5

Fig.4.1: Respondents level of satisfaction with their workplace noise level.27
Fig.4.2: Respondents level of satisfaction with their workplace lighting illumination.28
Fig.4.3: Respondents level of satisfaction with the air quality and temperature at
their workplace .29
Fig.4. 4: Respondent view on the extent of effects of noise, room temperature & air quality,
and lighting on their performance in productivity aspect..30
Fig.4.5: Respondent view on the extent of effects of noise from the weaving machine on
their performance in productivity aspects.....31
Fig.4.6 Respondent view on the extent of effects of noise, room temperature & air quality,
and lighting on their performance in productivity aspect..32
Fig. 4.7: Result of the survey in the weaving shop34
Fig.4.8: Result of the survey in the spinning shop35
Fig 4.9: Result of the survey in the finishing shop36
Fig.4.10 Clinical data analysis...38
Fig. 5.1: Quilted Fiberglass sound Absorbers43
Fig.5.2: Ear muffs..45
Fig. 5.3 Tornado Industrial Roof Ventilation Systems..48
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ABBREVIATIONS
ILO International Labor Organization

NIOSH - National Institute for Occupational Safety and Health
NPS - Nonwoven Porous Scrim Fabric
NRR - Noise Reduction Rate
OSHA - Occupational Safety and Health Association
PEL - Permissible Exposure Limit
PPE - Personal Protective Equipment
SCFC - Silicone Coated Fiberglass Cloth
VCFC - Vinyl Coated Fiberglass Cloth
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ABSTRACT
This thesis presents/discusses the quality of the employees workplace environment that most
impacts on the level of employees performance, conducted at a Bahir Dar textile share
company. Work in the present-day is predominantly performed indoors.
Indoor physical environmental factors (temperature, lighting, noise, dusts etc.) affect the
performance of humans. Since people are the most important resource and greatest expense of
any organization, the long-term cost benefits of a properly designed, user-friendly work
environment should be factored into any initial cost considerations. Many enterprises limit their
productivity enhancement of employees to the acquisition of skills. However, about 86% of
productivity problems reside in the work environment of organizations.
Annoying noisy produced by weaving machine, insufficient lighting, poor air quality in the room
and excessive hot temperatures are mostly familiar problems in textile industry. Generally due
consideration is not given to physical environmental aspects while designing individual
workstation/workplace/facilities in the organization/industry.
The objective of the thesis is to analyze the impact of physical work environment on workers
performance or productivity. This objective can be achieved through the care full identification
and study of the indoor physical work environmental factors (noisy, temperature, light intensity,
air quality& etc.) that has great impact on workers performance which in turn affects the firms
productivity.
The Investigation has revealed that factors of indoor physical work environment are responsible
for the enhancement of labors productivity. It also presented the proposed solutions to the
problems and ergonomic standard for physical work environment which will help the
organization in creating comfortable workplace environment where people enjoy what they do,
feel like they have a purpose, have pride in what they are doing, and can reach their potential.
BDU, IOT, School of Mechanical and Industrial Engineering Page IX

CHAPTER ONE: INTRODUCTION
1.1 Background of the study
The physical aspects of a workplace environment can have a direct impact on the performance,
productivity, health and safety, comfort, concentration, job satisfaction and morale of the
employee. Important factors in the work environment that should be considered include building,
workplace layout, temperature, ventilation, lighting, noise, vibration, radiation and air quality.
Good indoor environment is beneficial in terms of increasing productivity, satisfaction and
overall well-being of people.
This study focuses on analysis of physical work environment of Bahir Dar Textile Share
Company which has a great effect on the workers performance and the productivity of the
company. Specific focus area of the paper is on the spinning, weaving, and finishing shop of the
case company. In this thesis, problems resulting from inadequate physical work environment
related to workers performance and companys productivity are identified with justification and
the solution to the problem is proposed. The project is done to fulfill the partial requirement of
Bachelor of Science in Industrial Engineering.
In our country, previously there is no research done on this area and due consideration is not
given to physical environmental aspects while designing individual workstation/workplace in the
textile industries. Therefore, due to the above reason we plan to work on this area and we hope
that this paper will help industries and interested peoples in the field to get knowledge about the
physical work environment and its great relation to workers performance and companys
productivity.
BDU, IOT, School of Mechanical &Industrial Engineering Page 1

1.2 Objectives of the study
General objective:
The general objective of this study is to analyze the impact of physical work environment on
workers performance towards Companys productivity.
Specific objectives:
The specific objectives of the study are:

To investigate the major problems at the workplace of the case company regarding to
indoor work environment
To determine the effects of the problems on the individual performance with regard to
productivity.
To propose solutions that would help to alleviates the problems
1.3 Methodology
The purpose of this thesis is to investigate and propose possible solution by exploring and
describing factors that impact the workers performance in Bahir Dar textile Share Company.
Bahir Dar textile Share Company is selected as a case study for this research because:
There are many problem related with physical work environment in the company
rendering to reduced employees job performance
No emphasis is given to the physical aspect of work environment of a case company
In order to fulfill these requirements the study was done based on primary and secondary
sources. The primary data contains personal observation and measurement collected through
questionnaires and personal interviews with randomly selected workers and secondary data that
was found from the companys record, different ergonomics books, and websites.
Total of 44 employees were drawn randomly for questionnaires. Out which 16 are selected from
the total of 24 from the weaving shop, 20 from the total of 34 from spinning shop and 8 from the
total of 10 employees working in finishing department. Only operators are selected for the
questionnaires because they spend full working hours in the shop and they can give as accurate
data/information about their workplace environment
The data obtained from the questionnaire was validated through vetting (inspection) for
consistency and completeness. Subsequently, the responses were partitioned into homogeneous
sub-groups by department to facilitate analysis. The data was analyzed quantitatively using
graph, tables, pie charts, and etc. TES-1350A model sound level meter, liquid thermo meter, and
digital luxmeter (model: lx1010B) are used to measure sound level, temperature and illumination
level or light intensity at the workplace of weaving, spinning and finishing departments of a case
company respectively.
1.4 Scope of the thesis and Limitation
The scope of this thesis work is to focus on analyzing the impact of indoor physical work
environment of Bahir Dar textile Share Company on workers performance regarding to
productivity aspect and propose reliable solution to alleviate the problem. Main concern is given
to the physical working environment (Such as lighting system, noise, temperature, working area,
lay out, facilities in the work area, chemicals, air quality and etc.) of the spinning, Weaving and
finishing shop of the case company.
Some the challenges we had faced while doing this thesis are:
There is no book related with our title (ergonomics books) in the library due this we are
restricted only to search for literatures on some web site. But our school has not provided us
computer facilities on time. Therefore, to over com this challenges we have asked Mr. Tamirat
Tesfaye for his help by giving us his lap top and he has given it up to the last submission of the
thesis.
The measurement for the temperature in the spinning, weaving and finishing section of Bahir
Dar Textile Share Company is done only for one week due the shortage of time. Because more
time is spent on the getting the response from Amhara Regional State Bureau of Labors and
Social Affairs for the equipment requisition letter period of time, we cannot to take measurement
for a long. Lack of data about area the weaving, spinning and fishing shops of case company to
calculate the number of industrial roof ventilator required. Due to this we leave the calculation
for the company to do by showing the formula used to calculate the quantity of ventilators
required and the total cost of purchasing them.

1.5 Significance
Working environment plays a crucial role in enhancing the performance of an individual and the
organization as a whole. In poor working environment, it becomes particularly challenging to
maintain a productive and satisfying work life and in turn threatens the work success.
Good work environment should have to be created to increase productivity, satisfaction and
overall well-being of people. In order to address this issue, it is essential to better understand,
identify and consider the physical work environmental factors such as vibration, noise,
temperature, lighting system, etc) in designing the workplace/facilities in an organization.
The significance of this study, therefore, lies on indicating the determinants/factors of work
environment and their influence on the performance and well-being of the individuals. Bahir Dar
textile Share Company and other textile industries, employees of the case company, individuals,
societies or groups who are interested in studying the field ( physical work environment: an
ergonomics perspective) and other industries which needs to give high consideration of physical
work environment becomes the beneficiary from this thesis.
1.6 Structure and content of the thesis
The thesis is organized in six chapters. The first chapter begins with an introduction and
background of the thesis. Chapter two is literature review that discusses the fundamental concept
of indoor physical workplace environments and elements of physical workplace environment.
This chapter gives the theoretical background of the thesis work.
Problem identification is the third chapter in which major workplace physical environment
related problems in Bahir Dar Textile Share Company is identified with justification. Chapter
four is about the data collection. The data collected from Bahir Dar textile share company is
analyzed which would used in proposing of the solutions for the workplace physical environment
related problems. In fifth chapter the solution to the problems are proposed. Finally, in the last
chapter, the conclusions and recommendations have been presented.

INTRODUCTION
- Research background
- Research methodology
LITEATURE REVIEW ON PHYSICAL

WORKPLACE ENVIRONMENT
PROBLEM DATA COLLECTION

STATEMENT AND AND
JUSTIFICATION ANALYSIS
PROPOSED SOLUTION
CONCLUSION
AND
RECOMMENDATION
Fig.1: Organization of the thesis content

CHAPTER TWO: LITERATURE REVIEW
2.1 Introduction
Many business executives are under the mistaken impression that the level of employee
performance on the job is proportional to the size of the employees compensation package
(payment or reward). Although compensation package is one of the extrinsic motivation tools, it
has a limited short term effect on employees performance. A widely accepted assumption is that
better workplace environment motivates employees and produces better results [7].
Essentially, an elegant and functional workplace environment often culminates in improved

employee efficiency and productivity. The quest to equip employees and workers with most
suitable workplace environment, furniture, equipment, tools and techniques to discharge their
duties efficiently and effectively is the fundamental philosophy behind the development and
growth of ergonomics [9]. The performance of an employee is measured actually by the output
that the individual produces and it is related to productivity. At corporate level, productivity is
affected by many factors such as employees, technology and objectives of the organization. It is
also dependent on the physical environment and its effect on health and employees performance
[5].
2.2 Work Environment
Work environment is the totality of all physical, chemical, biological and psychological factors
at work which may affect the employees health and well being.
The physical aspects of a workplace environment can have a direct impact on the productivity,
health and safety, comfort, concentration, job satisfaction and morale of the people within it [1].
Important factors in the work environment that should be considered include building design and
age, workplace layout, workstation set-up, furniture and equipment design and quality, space,
temperature, ventilation, lighting, noise, vibration, radiation and air quality [1]. This thesis
focuses on analyzing the impacts of these factors on workers healthy, well being and their
performance regard to productivity. More emphasis is given to noise, temperature, and air quality
illumination level at shop of a case company.

2.2.1. Lighting
Light is the stimulus for vision. Thus, lighting has a significant effect on work efficiency,
comfort and safety [3]. Insufficient or too strong and particularly, glaring illumination causes
visual inefficiency, resulting in fatigue, headache, dizziness, and increased accident. Although
our eyes can adjust to a wide range of brightness, efficiency and safety will deteriorate unless
workers can clearly see what they are doing [3].
In workplace, lighting is needed to help employees in maintaining and generating their visual
tasks. Thus, lighting is crucial to enhance the effectiveness of visual review. There are three
important goals of using light in the workplace [1]:
generating an appropriate, adequate, and safe area for work,

forming pleasant and aesthetical vision, and
Saving energy.
An economic benefit sometimes associated with workplace lighting improvements is a reduction

in energy costs. Several approaches have been used to achieve this benefit. One way to improve
workplace lighting and to decrease lighting costs at the same time is to reduce overall
illumination from artificial light sources when it is too high. This reduction maybe accomplished
by replacing existing lamps with lamps having a lower lumen output and by removing lamps that
are not needed. Lighting costs will be significantly reduced, and employee productivity may
increase as well [13].
Another strategy for improving workplace lighting that also reduces operating costs is to increase
use of natural light by installing skylights and making other modifications to facilities. This
greatly reduces the amount of light required from artificial sources. Another advantage of using
daylight is that it illuminates walls and ceilings to create a more natural-appearing work space
[13].
A second economic benefit often associated with lighting improvements is better employee
productivity and reduces stress by making tasks easier to perform. Good lighting also creates a
pleasant working environment. This improves employee job satisfaction, reduces absenteeism,

and increases employee retention [13]. A third benefit frequently associated with lighting
upgrades is an improvement in employee well-being, which often leads to a reduction in
absenteeism and employee turnover. Employee well-being in this context refers to the overall
quality of working life in general but more specifically to job satisfaction [13].
Lighting affects our subjective impressions of our working environment, which ultimately affect
our behavior and job satisfaction. There are two kinds of light that are available to workplaces:
natural light and artificial light. Natural light is a free resource that enters the shop/office through
window or skylight, whereas artificial light is the kind of light which is produced and designed
by manufacturing [1]. A poor lighting system may cause fatigue or eyestrain which in turn
reduces employee performance as well as productivity.
Table 2.1: Recommended illumination level
Department/section Illumination level (Lux)

Minimum Maximum
1 Spinning 500 1000
2 Weaving 1000 2000
3 Finishing 200 500
Source: [13].
When selecting the lighting for a workplace, administrative office managers may have to
consider the ergonomics of lighting [1, 3]. A better lighting at the workplace will help prevent
accidents, help workers improve eye-hand coordination and thereby improve productivity and
lower rejection/defective rates. The company also will realizes intangible benefits that are
associated with better employee morale, reduction in accident rates because workers can see
what they are doing better.
The effects of poor light can include the following:
Low productivity
High human error rates
Inability to match or select correct colors
Eyestrain
Headache
A reduction in mental alertness
Dissatisfaction and
Low employee morale
Signs of visual fatigue are:
Pain full irritation and reddening of eyelids

Double vision
Headaches
Reduction in the power of accommodation and convergence.
2.2.2. Noise
Noise is another element of the workplace environment, which has an important role in affecting
employee performance. It is one of the leading causes of employees distraction, leading to
reduced productivity, serious inaccuracies, and increased job-r elated stress [4].
The two primary attributes of sound which are of great concern to ergonomist and safety
professionals are: the intensity or loudness of the sound energy measured in decibels (dB) and
frequency of the sound pressure wave measured in hertz (Hz) [1]. Excessive exposure to loud
noise can irreversibly damage the ear, resulting in noise-induced hearing loss. Noise is measured
in units of sound pressure levels called decibels, named after Alexander Graham Bell, using A-
weighted sound levels (dBA). The A-weighted sound levels closely match the perception of
loudness by the human ear. Decibels are measured on a logarithmic scale which means that a
small change in the number of decibels results in a huge change in the amount of noise and the
potential damage to a person's hearing.
Occupational Safety and health Association (OSHA) sets legal limits on noise exposure in the
workplace. These limits are based on a worker's time weighted average over an 8 hour day. With
noise, OSHA's permissible exposure limit (PEL) is 90 dBA for all workers for an 8 hour day.
The OSHA standard uses a 5 dBA exchange rate. This means that when the noise level is

increased by 5 dBA, the amount of time a person can be exposed to a certain noise level to
receive the same dose is cut in half [8].
The National Institute for Occupational Safety and Health (NIOSH) has recommended that all
worker exposures to noise should be controlled below a level equivalent to 85 dBA for eight
hours to minimize occupational noise induced hearing loss [5].
NIOSH has found that significant noise-induced hearing loss occurs at the exposure levels
equivalent to the OSHA PEL based on updated information obtained from literature reviews.
NIOSH also recommends a 3 dBA exchange rate so that every increase by 3 dBA doubles the
amount of the noise and halves the recommended amount of exposure time [8].
Here's an example: OSHA allows 8 hours of exposure to 90 dBA but only 2 hours of exposure to
100 dBA sound levels. NIOSH would recommend limiting the 8 hour exposure to less than 85
dBA. At 100 dBA, NIOSH recommends less than 15 minutes of exposure per day.
Table 2.2: permissible noise exposures OSHA standards
Duration per day, Sound level dBA slow

hours
response
8 85-90
6 92
4 95
3 97
2 100
1 102
1 105
110
or less 115
Source: [8].

When the daily noise exposure is composed of two or more periods of noise exposure of
different levels, their combined effect should be considered, rather than the individual effect of
each [8].
(1) (2)
If the sum of the following fractions: + (2) + ()/() exceeds unity, then, the mixed
(1)
exposure should be considered to exceed the limit value.
Where: D = noise dose during an 8 hr day;
() = Hours spent at a specified noise level; and
() = Total time of exposure (hours) permitted at that level.
The value of D must be kept below 1 or 100 % of permissible noise dose. Exposure to impulsive
or impact noise should not exceed 140 dB peak sound pressure level [8].
The noise level at r-feet (r-ft) away from the noise source can be calculated using the following
equation:
= 10 log(4 2 ) 10
Where: = the noise level at a point away from the noise source in decibels;
= the noise level at source in decibels; and
= the distance between the point and the noise source in feet.
2.2.2.1 Health effects of noise exposure
The health effects of noise exposure depend on the level of the noise and the length of the
exposure [8].
1. Temporary hearing loss
After spending a short time in a noisy workplace, you may have noticed that you cannot hear
very well and you have a ringing in your ears. This condition is called temporary threshold shift
[5]. The ringing and the feeling of deafness normally wear off after you have been away from the

noise for a short time. However, the longer you are exposed to the noise, the longer it takes for
your hearing to return to normal. After leaving work, it may take several hours for a worker's
ears to recover. This may cause social problems because the worker may find it difficult to hear
what other people are saying or may want the radio or television on louder than the rest of the
family [5, 8].
2. Permanent hearing loss
Eventually, after you have been exposed to excessive noise for too long, your ears does not
recover and the hearing loss becomes permanent. Permanent hearing loss can never be repaired.
This type of damage to the ear can be caused by long-term exposure to loud noise or, in some
cases, by short exposures to very loud noises [3].
When a worker begins to lose their hearing, they may first notice that normal talking or other
sounds, such as warning signals, are becoming unclear. Workers often adapt themselves hearing
loss produced by harmful noises at work. For example, they may begin to read lips as people
talk, but have difficulty listening to someone in a crowd or on the telephone. In order to hear the
radio or television they may need to turn up the volume so much that it deafens the rest of the
family.
Hearing tests are the only reliable way to find out whether a worker is suffering from hearing
loss. Unfortunately, hearing tests can be difficult to obtain and need to be performed by a trained
health-care professional. The reactions of new workers or visitors to a noisy workplace can be
indicators of a noise problem, for example if they have to shout, cover their ears, or leave in a
hurry.
3. Other effects
In addition to hearing loss, exposure to noise in the workplace can cause a variety of other
problems, including chronic health problems [5]:
Noise increases stress, which can lead to a number of health problems, including heart,
stomach and nervous disorders.
Noise is suspected of being one of the causes of heart disease and stomach ulcers.

Workers exposed to noise may complain of nervousness, sleeping problems and fatigue
(feeling tired all the time).
Excessive exposure to noise can also reduce job performance and may cause high rates of
absenteeism which in turn reduces the productivity of the organization/company.
2.2.3 Vibrations
Many workers do not think that their exposure to vibration could be a health hazard. Vibration
exposure is more than just nuisance. Constant exposure to vibration has been known to cause
serious health problems such as back pain, carpal tunnel syndrome, and vascular disorders [6].
Vibration related injury is especially prevalent in occupations that require outdoor work, such as
forestry, farming, transportation, shipping and construction. There are two classifications for
vibration exposure [6]:
Whole-body vibration, and
Hand and arm vibration
These two types of vibration have different sources, affect different areas of the body, and
produce different symptoms. Whole-body vibration is vibration transmitted to the entire body via
the seat or the feet, or both, often through driving or riding in motor vehicles (including fork
trucks and off-road vehicles) or through standing on vibrating floors (e.g., near shakeout
equipment in a foundry).
Hand and arm vibration, on the other hand, is limited to the hands and arms and usually results
from the use of power hand tools and from vehicle controls. Occupational health effects of
vibration result from extended periods of contact between a worker and the vibrating surface.
The health effects of chronic hand and arm vibration exposure are [6]:
decreased grip strength
decreased hand sensation and dexterity
finger blanching or white fingers
carpal tunnel syndrome
2.2.4 Temperature and Humidity
Indoor temperature is one of the fundamental characteristics of the indoor environment. It can be
controlled with a degree of accuracy dependent on the building and its heating, ventilation and

air-conditioning (HVAC) system. The indoor temperature affects several human responses,
including thermal comfort, perceived air quality, sick building syndrome symptoms and
performance at work [10].
2.2.4.1 Relationship between thermal environment and performance, productivity
A workers ability to do his/her job is affected by working in hot environments. One of the most
important conditions for productive work is maintaining a comfortable temperature inside the
workplace. Of course the temperature inside the factory varies according to the season and
several methods can be used to address the problem [5].
For workers in the textile industry, too much heat can result in the following health and safety
problems
Fatigue and dizziness

Heat stress/strain (distress)
Sweating palms (become slippery)
Heat exhaustion/heat stroke
Lower performance/alertness
Heat rash (prickly heat) and increased irritability.
2.2.5. Air Quality
The last element of the workplace environment, which has impact on employee productivity, is
air quality. Poor air quality can raise a negative impact on employee health in the form of
respiratory problems, headaches, and, fatigue, which in the long periods will reduce productivity
[4]. The work environment of most textile industries is polluted by the cotton dust particles and
chemical smell flowing in the air.
Cotton dust is defined as dust present in the air during the handling or processing of cotton,
which may contain a mixture of many substances including ground up plant matter, fiber,
bacteria, fungi, soil, pesticides, non cotton plant matter and other contaminants which may have
accumulated with the cotton during the growing, harvesting and subsequent processing or
storage periods [9].

Any dust present during the handling and processing of cotton through the weaving or knitting of
fabrics, and dust present in other operations or manufacturing processes using raw or waste
cotton fibers and cotton fiber byproducts from textile mills are considered cotton dust within this
definition [9].
Classification of Cotton Dust:
Cotton dust particles can be classified into four based on their sizes as shown in table below [9].
Table: 2.3 classification of dust based on size
Type Size of the particle (m)

Trash Above 500
Dust 50-500
Micro dust 15-50
Breathable dust Below 15
Source: [9]
The Micro-dust comprises 50-80% fiber fragments, leaf and husk fragments, 10-25 % sand and
earth and 10-25 % water-soluble materials. The high proportion of fiber fragments indicates that
a large part of the micro-dust arises in the course of processing. Nearly about 40 % of the micro
dust is free between the fibers and flocks, 20-30 % is loosely bound, and the remaining 20-30 %
bound to the fibers [9].
Types of Dust:
Inhalable Dust: It is a term used to describe dust that is hazardous when deposited
anywhere in the respiratory tree including the mouth and nose.
Thoracic Dust: It is defined as those materials that are hazardous when deposited
anywhere within the lung airways and the gas exchange region.
Respire able Dust: Respire able dust is defined as that fraction of the dust reaching
alveolar region of the lungs [9].

Health Hazards Associated with Cotton Dust Exposure:
Workers exposed to cotton dust burdened environment generally become patients of byssinosis.
Byssinosis is a breathing disorder (respiratory track) that occurs in some individuals with
exposure to raw cotton dust [9]. Characteristically, workers exhibit shortness of breath and/or the
feeling of chest tightness when returning to work after being in the mill for a day or more. There
may be increased cough and phlegm production.
It is believed that the degree or severity of response for individuals with symptoms of byssinosis
is related to the dust level in the workplace. The beginning steps in yarn preparation generally
produce more dust. Therefore, the closer to the beginning of the process, the higher will be the
dust level and the more likely the pulmonary reaction or response for some workers [9].
Table: 2.4 Permissible Exposure Limits (PEL) for Cotton Dust for Different Work Areas:
Department PEL (Micrograms per cubic

meter)
Opening 200
Picking 200
Carding 200
Combing 200
Roving 200
Spinning 200
Winding 200
Warping 200
Slashing 750
Weaving and 750
Knitting
Waste house 750
Source: [9]

2.2.6 Office furniture and Equipments
Selecting appropriate office furniture is another consideration in which office managers need to
pay more attention to make sure that the ergonomic environment is properly maintained. While
ergonomic environment is important in increasing employee productivity, adjustable office
furniture, such as desks and chairs, which can support employees in generating their work is
recommended, to allow the work comfortably throughout the day [4].
The consequence of selecting improper office furniture may be undertook for a long time, as it is
often difficult discarding the pre-owned furniture, which is commonly purchased rather than
leased or rented. There are several factors that need to be considered in obtaining of office
furniture: intended use of furniture, appropriateness of furniture in relation to dcor of office,
suitability of furniture, versatility of furniture, durability of furniture, hierarchical level of
furniture, size of furniture in relation to room or area size, and fire-retardant value of furniture
[1].
In addition to the furniture required for the office, a variety of office equipment is available.
Office equipment refers to office machines and devices that can be found in the office. Office
equipment is the intermediary between people and their work. Office equipment allows
employees to undertake not only more work, but also less time and better quality, for instance,
copier machines help employees in doubling documents in a short time [4].
Basically, in procuring office equipment organizations have two options: leasing and purchasing.
To those undertaking decision to obtain office equipment whether by leasing or purchasing need
to consider about the advantages and disadvantages of both options. While the useful life of
office furniture is generally quite long, making its better to purchase than to lease, the same is
not necessarily true of office equipment which is susceptible to much daily use and often
operating by different people as well as changes in technological advances. [1]
Other important aspects of selecting office equipment include ease to use, cost, dependability,
standardization, as well as equipment operator input. Organizations, which fail in obtaining
adequate office equipment, may reduce its employee satisfaction that may lead to lower
productivity [3]

CHAPTER THREE: PROBLEM STATEMENT AND JUSTIFICATION
3.1 Background of the case company
Bahir Dar textile Share Company was established as a state owned factory under the national
textile corporation in 1954 E.C with the aim of filling the demand gap of textile in the economy
where market competition was not the drive of the system. Then it was reorganized and re-
established as an independent beginner (pupil) enterprise in November 1984 E.C under
proclamation number 25/1984 E.C issued by the transitional government of Ethiopia.
Again it was re-established as a share company on September 1992E.C. The Bahir Dar textile
share company is an integrated textile mill which constitutes spinning, weaving, finishing and
garment machineries with its own favorable and complete infrastructure and support services. Its
capital amount at present day is 56,808,379,200 birr. It was implemented on the total area of
480,000 square meters; out of which 39,200 square meters is covered by building. The company
has employed about 1353 peoples in year 2004E.C. It manufactures a 100% cotton products
including yarns and fabrics. The main products of the company are; Bed sheets dyed and printed
fabrics, market yarn, and etc
3.2 Statement of the problems
In the spinning, weaving, and finishing shops of the company there are a number of different
machine on which workers spend their time working or operating each and every days. Weaving
and sizing machines produces annoying noise level and heat stress respectively, which will
create a potential health problems on the workers and will reduce their performance in
productivity aspects.
The following are some of the problems that results from improper design of physical work
environment and lack of proper safety devices/equipment occurring in the shops of the case
company.
Poor air quality (Exposure to cotton dust, bad smell of chemical, humidity and etc.),
Insufficient lights in the work shop (poor illumination level),

Annoying Noisy level produced by machines, and

Hot Temperature/Heat stress
Poor layout(lack of proper space between old weaving machines on the same row)
Each problem is discussed in detail as bellows.
3.2.1 Poor air quality
The environment of the three shops (spinning, weaving, and finishing) of Bahir Dar textile Share
Company is suffocating because it is contaminated by cotton dust particles fly in the room air,
soil dusts, and different chemical smells.
The workers engaged in the processing and spinning of cotton in the case company are exposed
to cotton dust. Exposure to cotton dust and other particles leads to respiratory disorders among
the textile workers. The fatal disease of byssinosis, commonly known as brown lung disease or
"Monday fever/metal fume fever", is caused among people working in the textile industry on
account of excessive exposure to cotton dust [5].
As the clinical data of the case company in table 4.2 shows respiratory track (respiratory
disorder) is mostly occurring problem on the workers of Bahir Dar textile Share Company in
spinning and weaving section. The symptoms of this disease include tightening of the chest,
coughing, wheezing and shortness of breath [5].
Cotton dust is often present in the air during cotton handling and processing. Cotton dust may
contain many substances including ground-up plant matter, fiber, bacteria, fungi, soil, pesticides,
non-cotton matter, and other contaminants that may have accumulated during growing,
harvesting, and subsequent processing or storage periods[5,6]. A Cotton dust particle has
different sizes which can be measured by micro-meters.
Those employees engaged in the spinning of cottons are also exposed to soil dusts that arise from
dirty cottons. The soil is deposited on the cotton during harvesting and storage. When processing
the cotton the soil dust are gets flowing in the room and causes a respiratory track on the
employee.

The weaving shop of the case company has the sucking device which moving through the shop
and sucks the cotton dust that has failed on the ground or floor. Since the device is closer to the
ground it only sucks the dusts of large sizes which have failed on the ground. Therefore, those
dusts of smaller sizes flies in air and cannot be sucked by the device.
These flying cotton dust particles when gets into the body of the operators through the mouth or
nose will affect their breathing system and reduces their performance with productivity aspect
over the time.
Workers in the finishing shop of the Bahir Dar textile share company are also exposed to a
number of chemicals, especially those engaged in the activities of dyeing, printing and finishing.
Chemicals based on benzidine, optical brighteners, solvents and fixatives, crease-resistance
agents releasing formaldehyde, caustic soda, stabilizer, sulfuric acid, flame retardants that
include organ phosphorus and organ bromine compounds and antimicrobial agents are used in
textile operations [5]. Studies have revealed that the links between exposure to formaldehyde and
nasal and lung cancer as well as to brain cancer and leukemia, which can be fatal. In the long
run, exposure to formaldehyde could lead to respiratory difficulty and eczema [5].
Operators of the case company who are engaged in dyeing, printing and finishing activities has
no proper personal protective equipment (such as glove, sturdy shoes and etc.) that protects them
from chemicals contacting their skin. Contact of the chemicals with skin as well as inhalation of
the chemicals can lead to several serious health effects such as eczema. The clinical data in table
4.2 taken from a companys clinical record shows the three major types of dieses resulting from
poor physical environment.
3.2.2 Illumination level
There are two sections in the weaving shop of the case company. In the first section which
contains old weaving machines has no proper lighting system (enough lights) when compared to
the second section which has enough lights provided for each machine. The fluorescence is
installed on the roof which is longer in height from the ground and it does not provide
appropriate illumination level due its location and dirtiness of the roof and fluorescence.

The light intensity of spinning, weaving, and finishing shop of Bahir Dar textile Share Company
is measured using a digital luxmeter. As the result of our measurement shows, the illumination
level in the first section of weaving shop is 893 lx which is below the minimum illumination
level (1000 lx 2000 lx) recommended by National Institute for Occupational Safety and Health
(NIOSH) whereas, the illumination level at the new weaving machines is 1560lx. Thus, operators
working on this machine cannot visualize or see immediately the yarn when it cuts. Therefore,
operators may take minutes to search for the yarn resulting in reduced performance in
productivity aspect.
3.2.3 Noise
Noise can be defined as undesirable sound to which an individual is exposed. It is one of the
leading causes of employees distraction, leading to reduced productivity over a time, serious
inaccuracies, and increased job-related stress experienced in the weaving shop of the case
company. The exposure to a noise level of 85 dBA 90 dBA at workplace for eight hour is
recommended by OSHA. But the noise level in a weaving shop of Bahir Dar textile Share
Company is 102.83dBA and all workers or operators of the shops are exposed to this noise level
for eight hours during a day.
3.2.4 Hot temperature
Another problem occurring in the shops of the case company is heat stress. The temperature of
spinning, weaving, and finishing room or shops is hot (especially warping section of spinning
shop). The operators of the sizing and jigger machine are exposed to steam or fume and heat
stress produced or released by the machine while it is working. The fume and steam are gas or
vapor produced when chemicals reacted and they are very dangerous for well-being of the
operators working in that area.
The average temperature around sizing machine is 102F (38.89C) on afternoon. The
temperature in the three sections of a case company is measured and the result of measurement
was summarized in table 4.1and table 4.2 shows the temperature measured for one week. The
result of the measurement shows the hotness of the shops which degrades the job performance of
employees as a temperature increases or rises. The Chronic heat exhaustion, sleep disturbances

and susceptibility to minor injuries and sicknesses have all been attributed to the possible effects
of prolonged exposure to heat [8].
3.2.5 Machine layout and work overload
Individual workers in the weaving shop of the case company are assigned to operate six weaving
machine. Therefore operators are required to perform a repetitive motion between the machines
to operate them. Due to this operators are exposed to fatigue, headache and muscular spasms.
During the observation we have been observing a machine cutting a yarn frequently within a
few minutes of operating time and the operators is tying the yarn. Sometimes two or more
machine stopped at the same time because the yarn is sliced down and then operators fix the yarn
and the machine starts working. As he/she fixed the problem of a first machine and go to fix the
second, he/she will get the first machine stopped again. All this repetitive between six machines
will result in reduced job performance of operator over the time as they spend more time in this
situation.
The old weaving machine of a case company is installed close to each other machines on the
same line. Therefore there is no proper clearance between each machine; as compared to the new
weaving machine which has proper clearance between each machine. This may result in a
difficulty for the maintenance of a machine when required. But the aisles in the shop are very
well spaced and are comfortable for easy movement.

CHAPTER FOUR: DATA COLLECTION AND ANALYSIS

4.1 Introduction
This chapter presents the analysis of the results of the field survey and discussion of the findings
of the study. It examines/analysis the ergonomics of indoor physical work environment and its
adverse effects on the performance of the employees regarding to the productivity. The studys
overriding concern is that the ergonomics, quality and functionality of the work environment
have a considerable influence on the level of employee productivity and overall performance.
Data is collected through a field survey, questionnaires and interviews with workers of the case
company, distributing questionnaire paper and by reviewing the documents of the company
which are relevant for this thesis. The questionnaires on the appendix A is distributed 44 in
copies to the respondent selected randomly from the operators of the case company. Out which
16 are selected from the total of 24 from the weaving shop, 20 from the total of 34 from spinning
shop and 8 from the total of 10 employees working in finishing department. Only operators are
selected for the questionnaires because they spend full working hours in the shop and they can
give as accurate data/information about their workplace environment
4.2 Working hour
The company has three working shifts and all the employees or worker of the company works
only one shift which is about eight hours in a day. The first shift starts at 2:00am and ends at
10:30 am, the second shift starts from 10:30 am and ends at 6:30pm, and the last/third shift starts
at 6:30pm and ends at 2:00am. The company provides only 30 minutes for a lunch/dining time
for the all workers of each shift. As we interviewed with the operators, they told us as there is no
additional time provided to them for a break. Thus, the time that employees spent working in the
company is eight hours per day.

4.3 Sound level, illumination level and temperatures at the workplace of Bahir Dar textile
Share Company
The actual values of noise level in dBA, light intensity/illumination level in lux and temperature
of the three sections of Bahir Dar Textile Share Company is measured using devices described
under methodology. TES-1350A sound level meter is used to measure the amount of sound at
workplaces (shops) of Bahir Dar Textile Share Company. It measures the sound level at
workplace with the accuracy of 2dBA.
Digital lux meter (Model: Lx-1010B) which has a capacity of measuring from 0-50,000lx is used
to measure the light intensity at three departments (spinning, weaving and finishing) of Bahir
Dar Textile share company. Whereas liquid mercury thermometer is used to measure the room
temperature of these three section. The measurement is done repetitively at different point and
time in each section to determine or obtain most accurate result.
The result of measurement is summarized in the table below for each section or department. The
range indicates the values in which temperature, noise level and light illumination level are
recorded during the measurement. The mean value is an average value of the readings obtained
from each measurement. It is the total values of individual reading divided by the total number of
readings made (frequency of reading). Temperature is measured for one week for spinning,
weaving and finishing section of case company and it is presented in the table 4.2.
Table 4.1 Measured values of noise level, illumination level, and temperature at Bahir Dar
Textile Share Company
Elements of physical Spinning Weaving Finishing

workplace environment
Range Mean Range Mean Range Mean
Noise level (dBA) 65-80 72 90-108 102.83 68-82 77
Average Temperature 23.9-33.89 27.28 25.56 -34 29.75 24-37.78 32
(C)
Light intensity (lux) 560-800 640 850-1800 893* 230-460 340
1560**
Source: Field survey, May 23, 2013 GC.

Where:
* = Average illumination level at old weaving machine
** = Average illumination level at new weaving machine
The table below shows the temperatures of the three shops of Bahir Dar Textile Share Company
measured using thermo meter during May 23-31, 2013 on working days for one week.
Table 4.2: Record of measured temperature in spinning, weaving, and finishing shop of Cause
Company
May May May May May May May

Time Department 23,2013 24,2013 27,2013 28,2013 29,2013 30,2013 31,2013
Morning Spinning 19.33 23.4 22 23.6 24.33 24.4 25

Weaving 24.10 23.8 24.6 23.12 24 21.2 22.5
Finishing 23.31 26 23.2 24.3 20 23.6 19
Afternoon Spinning 26.7 29.5 26.6 34.21 32.4 28.6 31.8
Weaving 29.33 26.25 36.4 29.33 33.53 29.5 30.6
Finishing 27.4 30.8 29.7 28.9 31.5 29.8 37.44
Source: Field survey, May/23/2013 May31/2013 GC
4.4 Demographic characteristics of the respondents
A total of 44 questionnaires were administered to the employees of Bahir Dar textile Share
Company who operate from the weaving, spinning and finishing shop. Out of this, 39
questionnaires representing 88 percent were completed and returned. About 54 percent of the
respondents were between 30-39 years old where others are between 20-30years old. Indeed 75
percent of the total respondents were male whiles 25 percent were female. All the respondents
that were drawn for the questionnaires were operators because they spend all their working hours
in the shop and therefore, they know well about their work environment. While others may goes
out of the shop and moves from shop to shops and they cannot affected by environmental factors.

4.5 Level of respondents satisfaction with physical work environment
The level of employees satisfaction with indoor physical work environment at their workplace is
assessed using the questionnaires and their responses to the questions are presented as below
using bar charts.
Noise level
Noise level is one of the ergonomic elements that impacts on employee communication and
cognitive activities. Responses were obtained on the noise levels at the shop of the case
company. The figure 4.1 shows the respondents satisfaction level with their workplace sound
level.
About 92% of respondents from spinning section are approved that their workplace sound level
is satisfactory and they stated reason of their satisfaction is that the shop is not too noisy.
Whereas the rest 5% & 3% of respondents replied that they are dissatisfied and very dissatisfied
respectively because they think off sound is too disturbing/noisy. In general the sound level in
spinning shop is not noise because it is safe according to the OSHA & NIOSH rule for noise
level at the workplace.
The respondents from weaving shop are approved or agree that the sound level in the shop is
very disturbing and noise. 90% of respondents are very dissatisfied and 8% of them are
dissatisfied with the noise. Whereas the rest 2% of respondents from weaving section are
satisfied with the sound level in the section.
Similar to the spinning section major respondents (86%) from finishing shop were satisfied with
the noise level in the section or at their workplace and they reason out that the reason for their
satisfaction as the sound in the section produced by machinery is not too noisy.
But 10 percent of respondents are dissatisfied and the left 4% are very dissatisfied with the noise
at the work. Standing on the level of respondent satisfaction level with the noise at their
workplace and the measurement we conclude that the noise level in weaving shop is the worst
one and it may need corrective action to be taken. Whereas the noise level in spinning and
finishing shops are safe.

100
92 90
90 86
80
70
Percent (%)
60
50 Satisfied
40 Dissatisfied
30
Very dissatisfied
20
10
10 8
5 3 2 4
0
Spinning Dep't Weaving Dep't Finishing Dep't
Department
Fig.4.1: Respondents level of satisfaction with their workplace noise level
Lighting/workplace illumination
Workplace illumination is one of the key elements of office ergonomics which has greater
influences in enhancing the workers performance and their satisfaction on job. The study
therefore sought respondents views on their workplace illumination levels as shown below. The
figure 4.2 shows that 75 percent and 62.5 percent of respondent from spinning and finishing
section respectively are satisfied with the lighting illumination at their work place which is 640
lux and 340 lux respectively at spinning and finishing section.
Whereas all the respondents working on the old weaving machine (56.25 percent) are dissatisfied
with the quality of lighting at their workplace because of poor illumination or insufficient
lighting (893 lux) which is below the recommended illumination level (1000 lux -200 lux on
weaving point) and thus they needs an improvement to be made on the lighting at the workplace.
Only 31.25 percent of respondents working on the new weaving machines are satisfied with the
illumination level at their workplace 1560 lux.

80 75
70
62.5
60 56.25
Percent (%)
50
40 Very satisfied
31.25 29.5
30 Satisfied
20 Dissatisfied
20
12.5
8
10 5
0
Department
Fig.4.2: Respondents level of satisfaction with their workplace lighting illumination

Room temperature and air quality
The most likely occurring problems on the workers of the Bahir Dar textile share company
are a respiratory tack and mental stresses t due to poor air quality and uncomfortable
workplace temperatures. The responses of the respondents on the question regarding
workplace air quality and temperatures are shown on the below figures. The figure 4.6 shows
that 65 percent of the respondents are very dissatisfied and 30 percents of them are
dissatisfied with the workplace air quality and temperatures. Only the rest 5 percents of
respondents are satisfied with the temperature and air quality of the shop in which they are
working.
Respondents complained of the cotton dust particles and soil dusts generated during the
processing as a contributing factor to the poor air quality and the failure of air
conditioners/ventilators as contributing factor to the hot stress in the shop of the factory.

90
80
80 75
70
60 56.25
Percent (%)
50
Satisfied
40
31.25 Dissatisfied
30
Very dissatisfied
20 15 15 12.5
10
10 5
0
Department
Fig.4.3: Respondents level of satisfaction with the air quality and temperature at their
workplace
4.6 Impact of indoor physical work environment on performance of employees
The study sought to find out whether spinning, weaving and finishing shops workplace
environment has any impact on the performance of its employees or not. What seems to emerge
is that although nearly all the respondents conceded(approved or agreed) that workplace
elements such as room temperature, air quality, noise level and quality of lighting, etc. have one
way or the other affected their performance, the extent of the impact varied from one employee
to the other.
Considering Bahir Dar Textile Share Companys workplace ergonomic elements and their
impact on employees performance, the study revealed that workplace elements (such as room
temperature, air quality, noise levels and quality of office lighting) negatively affect employees
performance at varying degrees. The respondents are asked to indicate the extent in percent to
which the physical environment affects their performance in productivity aspect and the analysis
is done on their response for each department using bar chart as follows.

4.6.1 Spinning department
Figure 4.4 show that 62.5 percent of the total respondents indicated that their workplace
temperature and air quality has impact on their job performance by between 50-60 percent.
About 16.67 percent of the respondents are in opinion that the effect room temperature and air
quality on their job performance is between 30% - 40%. Generally this shows as the spinning
section of a case company is has the problem of air quality and temperature. The temperature of
this section varies between 23.9-33.89C during a day.
Since the lighting and noise in spinning section is within the range of recommended level, about
62.5 and 54.17 percent respondents respectively showed their filling that there effect on job
performance is below 10 percent. It is familiar that human being differ in their hearing capacity
therefore about 33.33 percent of respondent are in opinion that the noise has influence on their
job performance in productivity aspect by between 10-20%.
70
Number of of respondent in Percent
62.5 62.5
60 54.17
50 Noise
40 33.33
29.17
30
20 16.67 Room
12.49 Temperature
10 4.17 8.33 8.33 4.17
0 4.17 0 0 0 & Air quality
0
Lighting
Level of environmental effects on performance of employee in

percentage
Fig.4. 4: Respondent view on the extent of effects of noise, room temperature & air quality, and
lighting on their performance in productivity aspect

4.6.2 Weaving department
Figure 4.5 below shows that 43.75 percent of the total respondents indicated that their workplace
noise level impacted negatively on their job performance by between 50-60 percent and where
31.25 percents of them are in opinion that the noise effect on their job performance is between
50-60 percent.
The response of respondent has also showed that room temperature and lighting at their
workplace has effect on their performance by between 30% - 40% and 70% 80% respectively.
All the respondent from old weaving machines (40% of respondent from weaving section) are
agreed that the illumination level at weaving point is not sufficient and they are facing the
problems such as eye strain, fatigue, double vision etc. All these resulted in reduced performance
on their job by 70% - 80%.
50
43.75
Number of respondents in percent
Noise
40 39 40
31.25
30 Room
22.5 23.5 25
Temperature
20 17.75
13.5 & Air quality
12.5
10 6.25 6.25 6.25 6.25 6.25 Lighting
0 00
0
Level of environmental effects on performance of employee in

percentage
Fig.4.5: Respondent view on the extent of effects of noise from the weaving machine on their
performance in productivity aspects

4.6.3 Finishing department
The response of employees from finishing shop on the extent to which noise, temperature& air
quality, and lighting affects their job performance in productivity aspect is presented using bar
chart on figure 4.6 below. About 54% of respondents are indicated that temperature and air
quality in section has negative impact on their performance in 50% - 60%. This section of a case
company has unfavorable temperature ranging from 24C - 37.78C.
This section of the company has appropriate illumination level (230 lux-460 lux) and sound level
(68dBA - 82dBA) as the result of measurement showed. Therefore about 46% of respondents
response approved that the effects of lighting on their job performance is below 10 percent.
Similarly 42percent of respondents are in opinion that the effects of noise on their performance is
below 10%. From this we can conclude that the finishing section of Bahir Dar Textile Share
Company has poor air quality and the temperature of the room is too hot. Therefore employees
of the section are showed their need for a better work environment.
Number of respondents in percent
60 54
50 46
42 Noise
40 35
30 25
20 15 16 Room
10 13 11
10 7 Temperature &
10 5 5 4 Air quality
00 2
0
Lighting
Leve of environmental effects on employees performance in percencentage
Fig.4.6 Respondent view on the extent of effects of noise, room temperature & air quality, and
lighting on their performance in productivity aspect

4.7 Result of the survey using checklist
We have evaluated the weaving, spinning, and finishing shops (departments) of Bahir Dar
Textile Share Company using the checklist of International Labor Organization (ILO) for
workplace environment which is shown on appendix 2. In addition to the observation and
measurement, interview is made with some operators at their workplace to make the evaluation
more accurate.
The result of our survey of the weaving, spinning, and finishing shop of the case company is
illustrated using a bar chart which shows the percent to which the question regarding noise, light
illumination, thermal condition and air quality for each shop is answered yes/no. Noise level is
one of the ergonomic elements that impacts on employees communication and cognitive
activities.
The ILO checklist for the ergonomic evaluation of the noise level at the work environment is
used to evaluate the work environment of the case company. A score with Yes referred to the
satisfactory work environment that mean work area of the departments meets requirements by
ILO standards for workplace environment (or the work area has fulfilled the required standards
by ILO) and No recommended some improvement in the available facility and ILO standards
for noise level is not fulfilled. There are seven check points as shown in Appendix B. Factory
scored high with No refer to poor working conditions.
The results of our survey of the weaving shop Bahir Dar textile Share Company are summarized
using the bar chart below.

Result of the evaluation

100
50
Percentange (%)
0
Noise Lighting Thermal Air quality
condition
Thermal
Noise Lighting Air quality
condition
Yes 3 35.71 66.67 16.67
NO 97 64.29 33.33 83.33
Fig. 4.7: Result of the survey in the weaving shop
The result for the evaluation shows that about 97% of the total does not satisfies the OSHA
standards for the noise at the work environment. This is because; the measured noise level in
weaving shop is ranging from 90-108 dBA. Only 3% of the total checklist is satisfied the
occupational safety and health standard for the workplace noise (answered yes). For example
question number seven regarding personal protective equipment is answered partially yes
because operators of new weaving machine are provided earplugs to protect them from hearing
problem whereas operators working on the old weaving machine havent provided with personal
protective device.
Similarly the average illumination level for the old weaving machine is 860lx on average which
is below the minimum recommended illumination level (1000-2000lx) and the average
illumination level for the new weaving machine is 1560lx which is in the range of recommended
illumination level. As we see from the figure 4.7 the weaving shop satisfies the standard or a
checklist is answered yes for 37.71 percent whereas it doesnt satisfy in 62.29

The percent can be obtained by adding the number of questions answered yes/no and then
dividing it by the total number of the questions and multiplying by 100. Some of the questions
are answered partially both yes and no. For example out seven questions regarding the noise only
the last question is answered yes. In general from the above analysis we conclude that the noise
level in the weaving shop is unfriendly while the thermal condition of the shop is satisfactory.

100
80
Percentage%
60
40
20
0
condition
Thermal
condition
YES 85.71 71.43 33.33 16.67
NO 14.29 28.57 66.67 83.33
Fig.4.8: Result of the survey in the spinning shop
The above bar chart shows that the noise and lighting of the spinning shop is satisfactory where
as the air quality and thermal condition of the room is not satisfactory. Out of the three questions
regarding the air quality, two questions are answered no and one is answered partially both No
and yes. This mean that about 83.33 percent of the questions regarding the air quality is
answered no which mean there is no satisfactory air quality in the spinning shop of Bahir Dar
textile Share Company.


100
80
Percentage (%)
60
40
20
0
condition
Thermal
condition
YES 100 42.86 33.33 16.67
NO 0 57.14 66.67 83.33
Fig 4.9: Result of the survey in the finishing shop
The finishing shop of the case company has no annoying noise level which can cause a hearing
problem and interfere or interrupt a communication between coworkers in the shop. The result of
our survey shows that there is satisfactory light and no satisfactory thermal condition and air
quality as shown on the figure above using a bar chart.
4.8 Clinical data
The clinical data was taken from the companys employees clinical record to investigate which
physical work environment is creating the greater impact on workers health and performance
regarding the productivity. A clinical data that shows the types of diesis and number of
employees affected by diesis for the past three years (2002, 2003, and 2004) as shown below.
Respiratory track (upper and lower respiratory track) that results from exposure to the dusts for a
prolonged period of time, eczema which caused by the exposure to the dusts and chemical odor
during finishing work and wounds due to chemical contacts are the dieses that are caused by the
poor physical working environment in Bahir Dar textile Share company.

Table 4.3: Clinical data taken from the companys document
Types of Total Number of Employees treated

dieses
Total
May
Mar
Aug
Nov
Apr
Jun
Feb
Dec
Jan
Sep
Oct
Jul
Year 2004,E.C
1 Respirator 45 30 59 46 72 68 104 75 44 81 64 11 800
y track 2
2 eczema 0 0 0 0 0 61 0 35 0 52 26 50 224
3 Wound 5 0 2 0 0 0 0 3 6 0 0 8 24
Year 2003 E.C
1 Respirator 38 74 68 71 61 54 58 55 39 29 78 53 678
y track
2 eczema 5 0 0 10 3 9 25 0 2 7 12 31 104
3 Wound 6 1 0 0 0 2 0 0 4 0 0 0 13
Year 2002,E.C
1 Respirator 5 16 31 10 0 9 11 42 56 61 3 22 266
y track
2 eczema 2 1 0 1 0 0 0 3 1 5 4 8 25
3 Wound 0 7 1 2 0 1 9 0 0 6 9 8 43

900
800
Number of employees treated 800
678
700
600
500
Respiratory track
400
Eczema
266
300
Wound
200 224
104
100 43
0 25 13 24
2002 2003 2004
Year EC.
Fig.4.10 Clinical data analysis
This clinical data of the company shows that the most of employees (operators) are affected by
the respiratory track dieses and the number of employees affected by the dieses is increasing
over the years. This is because the work environment of the company has no satisfactory (pure)
air quality and employees are exposed to the cotton dusts particles and soils dusts from cottons
during processing it. As employees stay servicing in a company for a long year as exposed to the
cotton dust, they will become the patient of respiratory dieses due this a number of employees
treated for this dieses become increased over a year.
As we see from table 4.2 there are employees treated for the dieses type eczema during the five
months from September to January this is may be because of weather condition or quality of
cotton processed during this months. It may also due to the workers are not exposed to hazardous
chemical smell.

4.9 Discussions of findings
The finding from the study to a considerable extent validates and brings to reality the widely
accepted assumption that a better workplace environment motivates employees and produces
better results.
The study demonstrated that workplace ergonomics deficiencies at the Bahir Dar textile share
companys production shop which includes hot temperature and poor air quality variedly
impaired the performance of an average employee by between 50 to 60 percent in spinning and
finishing section, and between30% to 40% in weaving shop.
The measured result of temperature, noise level and light intensity in table 4.1 also realized that
the sound level in the weaving section is 102.83dBA and is very noisy. Thus the study has
showed that the noise level at this section has affected the job performance of employees by
percent of between 70% and 80%. It also indicated that about 54.17% of respondents from
spinning and 46% of respondents from finishing section are approved that the effect/impact of
noise on there is below 10 percent.
The study has also showed that the lighting at the weaving is insufficient and impaired the job
performance of the employee by between70% to 80%. There is a good illumination level in the
spinning and finishing departments of the case factory. Thus, respondents from the two sections
are in opinion of that the lighting has only below 10% effect on their job performance.
A companys clinical record is also a good indicators that the impacts of temperature and air
quality on employees well being and job performance.

CHAPTER FIVE: PROPOSED SOLUTION TO THE PROBLEMS
5.1 Introduction
The healthy workplace environment creates more satisfied workers and leads the organization
into profitability and productivity. Therefore, an organization should has create comfortable and
health workplace environment to become profitable and productive through satisfied and wealth
workers. But the reverse is true in Bahir Dar Textile Share Company, where employees are
dissatisfied with their workplace environment and are exposed to health problems.
The study demonstrated that workplace ergonomics deficiencies at the Bahir Dar textile share
companys production shops which include hot temperature and poor air quality variedly
impaired the performance of an average employee by between 50 to 60 percent in spinning and
finishing section, and between30% to 40% in weaving shop.
The study has also showed that the lighting at the weaving is insufficient and impaired the job
performance of the employee by between70% to 80%. The sound level of 102.83dBA is
recorded in the weaving section and which exceeds the allowable or permissible sound level (85-
90dBA in eight hour exposure time) by OSHA. Thus, the noise level at this section has affected
the job performance of employees by percent of between 70% and 80%.
Therefore, this study is aimed at solving the problems of physical work environment of a case
company. The solutions that will help to alleviate these problems are proposed under in this
chapter as bellow.
5.2 Methods of noise control
Workplace noise can be controlled:

At the source;
Along the path between the source and the worker (through the use of barriers); and
At the worker.
In common with all control strategies for health and safety problems, the most effective method
is to control the hazard at source. However, this often requires a considerable expense and, with

profitability being cut to a minimum in the global market, owners and managers is often dislike
spending money in this area. The least effective, but most common and cheapest method of
control is to put the emphasis on workers wearing some form of personal protective equipment
(PPE).
5.2.1 Controlling at the source
As with other types of exposures, the best method of prevention is to eliminate the hazard.
Therefore controlling noise at its source is the best method of noise control. It can also often be
cheaper than other methods of noise control. This can be done by the manufacture, through
engineering changes on the source itself, through regular maintenance, lubrication and
replacement of parts, or by changing the way materials are handled. Noise can be controlled at
the source by the manufacturer, so that noisy devices never reach your workplace.
Ideally, any machines in the factory should conform to national and international standards and
not produce noise levels above 85 dBA in the first place. Unfortunately, many of the machines
are old, require regular servicing, and should be replaced when possible. Whereas weaving
machine in textile factories produces a noise level of 102.83dBA.
Against this background, there are a number of mechanisms that can be used to control/reduce
noise levels at source including:
Purchase quieter machines;
Enclosing entire machines or particularly noisy parts of machines with soundproof cover
Regularly servicing and maintaining machines;
Replacing worn or defective machine parts;
Reducing the vibration in component parts and casings.
Ensuring that the machines are mounted correctly on rubber mats or other damping
material and that mounting bolts are secured tightly;
Replacing metal parts with others made of sound absorbing materials e.g. plastic or
heavy duty rubber;
Fitting mufflers (covers) on exhaust outlets and direct them away from the working area.
Sound absorber:

Quilted Fiberglass Absorbers (QFA), are fire safe, high performance acoustical fiberglass
blankets that are used to reduce reverberant (reflected) airborne noise energy in many diverse
industrial and architectural applications as well as on original equipment. They are an excellent
alternative to urethane foams since they are fire safe, exhibit low smoke emissions and possess
high mechanical strength. Additionally, they have a wide range of temperature limits, can be
cleaned, and are unaffected by moisture, humidity, dust, dirt, oils, and most chemicals. Flexible
quilted absorbers are easily installed, will not degrade, and have extremely long service lives.
Unit price $350.
Among different models available we have selected model number QFC-1 for Bahir Dar Textile
Share Company because it has highest noise reduction rate. One piece of the roll can be divided
or partitioned into 152 parts (16 inch width*5 inch length) and hanged on the roof and above the
weaving machines. Thus, two pieces of the roll is required to install above all the machines.
Therefore; the total cost of Quilted Fiberglass Sound Absorbers will be:
Total cost = $350*2pieces = $700 or
= Br13, 090
Table 5.1: Specification of Quilted Fiberglass Sound Absorbers
Model Product description Nominal Roll Width Roll Length NRR

Thickness (dBA)
QFA-1 Single layer fiberglass, one side 1 inch 48 inches 50 feet 16
faced with (VCFC), opposite side (2.54cm) (121.92cm) (3870.96cm)
faced with (NPS)
QFC-2 Single layer fiberglass, one side 1 inch 48 inch 50 feet 18
faced with SCFC, opposite side (2.54cm) (121.92cm) (3870.96cm)
faced with NPS
QFA- Double layer fiberglass both sides 4inch 48 inch 25 inch 20
10 faced with (VCFC) (10.16cm) (121.92cm) (1935.48cm)
Source:[ http://www.industrialnoisereduction.net/qfas.html]

Install quilted fiberglass absorbers in locations indicated. Comply with manufacturers written
instructions for installation of panels or rolled goods using type of mounting accessories
indicated or, if not indicated, as recommended by the manufacturer. The selected model of
quilted fiberglass sound absorber will reduce the noise level in the weaving shop of case
company by 20dBA and the noise level reaching the operators ear may reduced to 82.83dBA
after installing it. The figure below depicts the quilted fiberglass sound absorber.
Fig.5.1: Quilted Fiberglass sound Absorbers

[http://www.industrialnoisereduction.net/products.html; June 6, 2013 7:22am]
5.2.2 Controlling noise along the path between the source and the workers
If it is not possible to control the noise at source, then methods can be used to minimize the
spread of the sound waves in the factory. Accordingly, any method that can be used to stop the
spread or absorb the sound waves can effectively reduce the noise problem. Such methods
include:
Using sound absorbing materials where possible on the walls, floors and ceilings;
Placing sound absorbing screens between the source of the noise and workers;
Hanging sound absorbing panels from the ceilings to capture some of the sound waves
and reduce the overall noise level;
Build sound-proof control areas and rest rooms;
If possible, increase the distance between a worker and the source of the noise.
[

5.2.3 Controlling the noise at the worker
The most common form of noise control is the use of personal protective equipment in the
form of hearing protectors. They work on the principle of preventing damaging sound waves
from reaching the sensitive parts of the inner ear. There are basically two types of protectors (ear
plugs and ear muffs).
Ear plugs are worn in the internal part of the ear and they are made of a variety of materials
including rubber, moldable foam, coated plastic or any other material that will fit tightly in the
ear. Ear plugs are the least desirable type of hearing protection from an efficiency and hygiene
(cleanliness) perspective. On no account should workers be encouraged to stuff cotton wool in
their ears to act as some form of ear plug all that happens is that some of the cotton wool gets
left behind when the plug is removed and causes an ear infection.
From a health and safety perspective, ear muffs are more efficient than ear plugs providing they
are worn correctly. They must fit over the whole ear (not press the ear flap against the side of the
head) and seal the ear from the sound waves. Workers who have beards or wear glasses have
difficulty in getting a tight seal around the ear.
Ear protection is the least acceptable method of controlling an occupational noise problem
because:
The noise is still present: it has not been reduced;

In hot, humid conditions workers often prefer earplugs (which are less effective) because
earmuffs make the ears sweaty and uncomfortable;
Management does not always provide the correct type of ear protection: often it is a case
of the cheaper the better;
Workers cannot communicate with each other and cannot hear warning signals;
If ear protection is provided instead of controlling the noise at source, then management
is putting the responsibility on the worker and it becomes the worker's fault if he or she
becomes deaf.

Providing workers with ear protection is the least acceptable method of noise control. However,
if this is the only solution, then earmuffs are a better choice than earplugs.
Noise reduction rating of PPE
Noise Reduction Rating (NRR) is the measurement, in decibels, of how well a hearing protector
reduces noise as specified by the Environmental Protection Agency [14]. The higher the NRR
number the greater the noise reduction. While wearing hearing protection the exposure to noise
is equal to the total noise level minus the NRR of the hearing protectors in use. For example, if
somebody were exposed to 80db of noise but were wearing earplugs with an NRR of 29, his/her
actual noise exposure would only be 51dB.
When dual protectors are used, the combined noise reduction rate provides approximately 5 - 10
decibels (dBA) more than the higher rated of the two devices. For example using ear plugs (NRR
29dB) with ear muffs (NRR 27dB) would provide a Noise Reduction Rating of approximately 39
decibels look at the figure 5.1 below.
Fig. 5.2: Ear muffs [source: Cooper safety; http://www.coopersafety.com/]
The noise in the weaving department of the case company cannot be controlled at the source or
using a barrier because the parts of the machine producing the noise cannot be isolated or
enclosed by silencer and distance between workers.
Therefore the only solution to the problem is providing dual hearing protectors (i.e. ear plugs
with ear muffs) to the operators of weaving and providing enough break time to restore workers

from hearing problem and other health effects of noise. This dual hearing protector will reduce
the noise level in the weaving department by 39 dBA from 102.83 dBA to 63.83 d BA.
Both ear plug and ear muffs shown on figure 5.2 together costs $24.73 (Br. 462.45). Therefore
the total cost of providing dual hearing protector is the product of unit price (Br. 462.45) and
total employees provided the device.
Total cost of providing employees this device will be:
Total cost = total number of operators of weaving machine* unit price (Br462.45)
= 31 employee*Br462.45
= Br14, 335.95
Since the cost of using quilted fiberglass sound absorber and the cost of proving personal
protective equipment is almost equal, it is better to provide PPE to workers because it can reduce
the noise level reaching to the ears of operators to 63.83dBA. But using the sound absorber on
ceiling only can reduce the noise level in the room to 82.83 dBA.
5.3 Methods of controlling Lighting illumination
From the workers perspective, poor lighting at work can lead to eye strain, fatigue, headaches,
stress and accidents. On the other hand, too much light can also cause health and safety problems
such as glare headaches and stress. Both can lead to mistakes at work, poor quality and low
productivity. Various studies suggest that good lighting at the workplace pays dividends in terms
of improved productivity and a reduction in errors [5].
Improvements in lighting do not necessarily mean that you need more lights and therefore use
more electricity it is often a case of making better use of existing lights; making sure that all
lights are clean and in good condition; and that lights are positioned correctly for each task. It is
also a case of making the best use of natural light.
The lighting problem (insufficient lighting) in the weaving department of Bahir Dar Textile
Share Company can be solved through:

Ensuring good lighting at all times through testing and regular maintenance. It has been
estimated that the output of a typical lighting unit decreases by 25% six weeks after it is
installed [14].
Testing lighting levels, to ensure that the proper lighting level is maintained using a light
level meter. For example; test after lights have been used about 100 hours, and at regular
intervals.
Developing a schedule to clean lighting units and workplace surfaces, such as walls and
ceilings and to replace bulbs (fluorescence or tubes) before they burn out.
Increasing reflectance of room surfaces, for example changing decor to light colors
Removing obstructions and decreasing spacing of luminaries or provide more fittings
Make close the fluorescence to ground or reduce the height of the fluorescence location
by hanging it on the roof.
Installing the fluorescence for each old weaving machine like the new machine is the best
solution. There are about 120 old weaving machines. Installing fluorescence on each machine
will cost the company Br5600 (total cost of fluorescence plus the cost of wires). Since the
company has its own electrician no cost will be incurred for installation.
Total cost of fluorescence = total number of machines*unit price the fluorescence
= 120*Br45
= Br5400
5.4 Methods of controlling heat stress
A workers ability to do his/her job is affected by working in hot environments. One of the most
important conditions for productive work is maintaining a comfortable temperature inside the
workplace. Of course the temperature inside the factory varies according to the season and
several methods can be used to address the problem.
There are a number of basic approaches to tackling heat hazards in textile factories. All involve
reducing exposure by keeping heat away from workers through:
Engineering controls;

Changing work practices;

Use of personal protective equipment (as a last resort/alternative).
i. Engineering controls:
Engineering control may include the following:
The use of increased general ventilation throughout the factory by opening windows, by
ensuring that air bricks, doors etc are not blocked;
The use of spot cooling by the use of fans to reduce the temperature in certain sections
of the factory (the correct placement of fans is essential);
The use of local exhaust ventilation systems in hot spots such as the warping and
finishing section to directly remove the heat as close to the source of the heat as possible;
The use of air conditioners or refrigeration systems to cool air and reduce the humidity.
Using industrial roof ventilation system: the industrial ventilation system supplied by
South Africa is installed on the top of the roof as shown on the figure5.2 below
Fig.5.3: Tornado Industrial Roof Ventilation Systems [source:

www.windmaster.co.za/tornado_industrial.htm]
Determination of number of the ventilators required
The number of tornado industrial ventilator required for any shop (room) can be determined
based on the total volume of air change required in the shop and the extraction capacity of the
ventilator. The extraction capacity of the ventilator varies based on their sizes.

For Bahir Dar Textile Share Company we have selected the galvanized Tornado ventilator of
size 300mm and weight of 7.6kg. It has the air extraction capacity of 1863m3/h (meter cube per
hour) at 15 kilometer per hour (km/h) wind speed and 2184m3/h (meter cube per hour) at 25
kilometer per hour (km/h) wind speed. Require number of ventilator can be determined using the
formula:

of ventilator required =
Extraction capacity of the ventilator
Where:
Total volume of air in the room = Volume of the room*rate of air flow required
= (length*height*width)*rate of air flow required
The rate of air flow is measured in air changes per hour. An air change per hour (ACH) is the
volume of air that needs to be replaced with fresh air every hour. The rate of air changes required
for factories and workshops ranges from 4 to 6 and for dying section it ranges between 10 and15
airs change per hour is required. Thus average air changes of 12.5 per hour is taken for dying
section and air changes of 5 per hour for all other sections of factory (Bahir Dar Textile Share
Company).
Tornado Industrial Roof Ventilation Systems installation procedures
The tornado industrial roof ventilator can be installed easily and economically using the
following procedures on the top/roof of the work shop:
1. Place the base plate onto the roof and mark the hole to be cut. Ensure that the base plate
is pushed under the ridge cap.
2. Cut the marked hole square with an angle grinder.
3. Bend the sheeting back at the bottom end of the cut out and remove closure from under
ridging
4. Insert closure at the bottom end of base plate and pop rivet the base plate onto the roof
5. Waterproof base plate using silicon or membrane and sealer.
6. Place the throat and dome section onto the base plate

7. Make sure that the locking brackets are loose

8. Adjust throat in order to get the top section of the throat and the dome in a level position
9. Fasten the locking brackets
10. Fix the throat onto the base plate by drilling and using pop rivets.
11. If more than one unit is required stagger the units across the roof
This step was supported with a figure that shows the steps or procedure to be followed to install
the tornado industrial roof ventilation system. The image or figure was indicated on the appendix
c.
Benefits of Industrial Roof Ventilation Systems:
Positive extraction removes heat, fumes, steam and dust.

Improves productivity through creation of good and motivating work place
environment
Improves indoor air quality
Reduces structural damage.
Human and environmentally friendly (create/pose no environmental or pollution related
threat).
No maintenance or operating costs (because it works or operated by air wind)
The rotating turbine action removes convicted heat and induces currents of fresh air to
flow within a building producing a substantial cooling effect on people and the
environment in general
ii. Changing work practices
Changing the work practice is one of the management control/solution to problem of room
temperature. The following are some the mechanisms to be used as a management control to the
problem:
Increasing the number and duration of rest periods;

Introducing job rotation so that workers are not always doing so-called hot work;
Doing hot work in the coolest part of the day;

Providing more workers to reduce the work load so that workers spend shorter times in
hot environments.
Whatever method is used to reduce workplace temperature, it is important that if adequate

supplies of drinks are made available to workers. These drinks could be cool, diluted fruit juices
or lemon tea because water alone will lead to muscle cramps etc.
5.5 Methods for monitoring air quality
The quality of air in the shops of the case company has been affected or contaminated by dust
particles and odor of chemicals used in the finishing and warping room. To avoid the dust
particles failing on floor, the dust sucker is provided in the weaving machine. The sucker moves
around all machines and sucks only those dusts of larger in size failed on the shop floor. But this
is not enough to avoid dusts because it does not suck small sized dusts flying in the air and
reduce the quality of the air.
The air quality can be maintained by:

Providing enough windows which can avoids or reduces the amounts of the dusts in the
room/shop by allowing and facilitating the air circulation.
Providing operators a safety device which protects them from the dusts or chemical odor
entering into their body through mouth or nose. Especially workers who are engaged in
the finishing room must be provided personal protective equipment (for example mask,
helmet) which protects them from the chemical odors entering into their body through
their nose and mouth.
Tornado industrial roof ventilation system is the best mechanism for conditioning room
air quality by allowing and regulating air to flow out and in from outside. When this
ventilator is used the air quality of the shops of Bahir Dar Textile Share Company can
becomes comfortable.

CHAPTER SIX: CONCLUSION AND RECOMMENDATION

6.1 Conclusions
This study has assessed the impact of indoor physical work environment on the performance of
Bahir Dar Textile Share Company employees operating from weaving, spinning, and finishing
section. The results from the study confirm that indoor physical work environment ergonomic
deficiencies at these sections are impacting or reducing the job performance of employees over
the time.
From the findings of the study, which identifies substantial workplace physical environment
ergonomic lapse such as inadequate lighting, irritating noise level, high room temperature, and
poor air quality, it is obvious that Bahir Dar Textile Share Company is yet to leverage on its
workplace environment as a means of motivation and enhancing the performance of its employee
for a better productivity and profitability. Excessive noise exposure is a high risk for the hearing
of workers. It has been noted that the weaving section has a very high sound level. In our study
mean sound levels in the weaving sections were102.83 dB (A) with a range of 90-108 dB (A).
In order to alleviate the current situations of indoor physical work environment of Bahir Dar
Textile Share Company, we have proposed possible solutions based on the above findings. And
we hope if implemented by the company, the solutions will alleviate these problems and help to
boost the job performance of the employees.

6.2 Recommendations
In view of the findings and conclusion of the study, the following recommendations are made for
consideration by Bahir Dar Textile Share Company as means of utilizing its workplace
environment to motivate and enhance the job performance of its employees.
The development and implementation of health and safety policy to help identify and deal with
health and safety hazard at Bahir Dar Textile Share Companys production shops is strongly
recommended.
Lastly, employee should be made to undergo training on workplace ergonomics issues such as
work related hazards and injury, health hazards of noise, in adequate lighting, air quality and
thermal condition at their workplace and how to avoid these health effects and injuries.
We would also like to recommend the company to take the following actions. The company
should:
Motivate its workers

Be aware of its employee because they the key to the companys survival
Consult with colleagues and supervisors about possible hazards
Walk through the work site and record any hazards
Analyze workplace incident, accident, injury and illness data
Consult with specialist practitioners, industry associations, unions and government
bodies.
Consider likelihood of occurrence and severity of consequences while assessing the risk
at work place.

REFERENCE
1. http://workspacedesignmagazine.com/2012/08/ergonomics-and-workplace-design/
2. http://www.ncsu.edu/aern/TAS12.1/TAS12.1Ajala.pd(africansyposium)
3. Mc cormic,Ernest James, Human Factors In Engineering and Design, Fifth edition
4. http://www.elsevier.com/locate/apergo
5. http://www.actrav.itcilo.org/actrav-english/telearn/osh/noise/nomain.htm
6. http://www.statefundca.com/safetymeeting/safetyMeetingArticle.aspx?ArticleID=80
7. The impact of office ergonomics on employee performance; a case study of the Ghana
national petroleum corporation (gnpc) by Asante Kingsley (pg. 4095010)
http://dspace.knust.edu.gh:8080/jspui/bitstream/123456789/4938/1/ASANTE%20KINGS
LEY.pdf
8. United State Department of Labor

http://www.osha.gov/pls/oshaweb/owadisp.show_document?p_table=STANDARDS&p_
id=9735
9. Cotton dust - Impact on human health and environment in the textile industry By: R.
Senthil Kumar
http://www.fibre2fashion.com/industry-article/9/831/cotton-dust-impact-on-human-
health-and-environment-in-the-textile-industry1.asp
10. Effects of Heat Stress on Working Populations when Facing Climate Change by:
Karin LUNDGREN1*, Kalev KUKLANE1, Chuansi GAO1 and Ingvar HOLMR1
https://www.jstage.jst.go.jp/article/indhealth/51/1/51_2012-0089/_pdf
11. Thermal Environment and Productivity in Sedentary Activities. A Short Review
Quelhas Costa, Emliaa; Santos Baptista, Joob; Tato Diogo, Miguelc
http://repositorio-aberto.up.pt/bitstream/10216/65170/2/950507.pdf
12. http://www.google.com.et/url?sa=t&rct=j&q=what%20illumination%20level%20is%20recomme
nded%20at%20weaving%.ZGU
13. Ergo Dynamix - Workplace Lighting [ http://www.ergodmx.com/articles/article_8.html]
14. Wind mater;[ http://www.windmaster.co.za/tornado_tech_info.htm]

APPENDIX-A: QUESTIONNAIRE FOR DATA COLLECTION
Topic: Analyzing the impact of indoor physical work environment on workers

performance (A case study of Bahir Dar textile Share Company)
Introduction:
This is an academic exercise aimed at gathering primary data towards the writing of a thesis on
the above topic. Your co-operation in providing honest and prompt responses to the
questionnaire would be very much appreciated.
Section a: socio-demographic data of respondent
Encircle on the letter for your answer
1. Gender: A. Male B. Female
2. Age: A. 20-29 yrs. B. 30-39 yrs. C. 40-49 yrs. D. 50 yrs. and above
3. Level of work: Machine Operator
4. Division/Department/Unit __________________
5. Length of service at Bahir Dar textile Share Company:
A. 0-1 year B. 2-3 years C. 4-6 years D. 7-9 years E. 10 years or more
Section b: Level of employee satisfaction with physical work environment
6. Please indicate your level of satisfaction with each of the under listed workplace elements
using the ratings from 1 to 5 described below (by ticking) as:
1-Very Satisfied 2-Satisfied 3-Dissatisfied

4- Very Dissatisfied 5- Undecided

Note: For each response kindly indicate the reason for your choice. You may use the sample
reasons below the table as a guide.
TableA1: Employee satisfaction with workplace physical environment
Brief Description of Workplace Elements 1 2 3 4 5
1 Easy of communication and collaboration

Reason:
2 Level of noise from the weaving machine
Reason:
3 Room temperature and air quality
Reason:
4 Quality of lighting- artificial lighting
Reason:
Sample Reasons:
The shop is dark and not lively/vigorous

There is a sufficient illumination
The shop is noisy/quite enough
The shop is well air-conditioned and comfortable
There is ease of communication
Section c: Impact of physical work environment on employee performance
Encircle on the letter for your answer
7. Please select the option below that best describes your current work environment
A. Highly Impressive B. Impressive C. Least Impressive

D. Indifferent E. Not Impressive F. cant tell
8. Indicate to what extent your current work environment is a source of motivation to your job
performance
A. Highly Motivating B. Motivating C. Least Motivating

D. Indifferent E. Not Motivating F. Cant tell

9. Is your workplace environment quiet enough for productive work?

A. Always B. Mostly C. Often
D. To some extent E. Not at all
10. Is your workplace room temperature conducive (favorable) enough for productive work?
A. Always B. Mostly C. Often
D. To some extent E. Not at all
11. Is your workplace room/shop well illuminated for productive work?
A. Highly illuminated B. Illuminated C. Fairly illuminated
D. Poorly illuminated E. Not at all
12. Using the scale below, please indicate the extent (in percentage) to which the workplace
elements affect your job performance by ticking.
a) Below 10% - 0
b) Between 10% - 20% - 1
c) Between 30% - 40% - 2
d) Between 50% - 60% - 3
e) Between 70% - 80% - 4
f) Between 90% - 100% - 5
TableA2: Effect of work place elements on employees performance regarding productivity
Brief Description of physical workplace elements 0 1 2 3 4 5

1 Easy of communication and collaboration
2 Level of noise from the weaving machine
3 Room temperature and air quality
4 Quality of lighting- artificial lighting
THANK YOU VERY MUCH FOR YOUR PATIENCE AND RESPONSES!
APPENDIX- B: CHECKLIST
The checklist for evaluating the ergonomics of workplace environment of Bahir Dar Textile
share company production shops is given in the table on the next page.

Table B1: An Ergonomics Checklist for Enhancing Comfort, Health and Performance in a
weaving, spinning and finishing shop of the case company
Questions Responses
Yes No Remark
Noise
1 Are noisy parts or machines enclosed or covered completely?
2 Are machines serviced regularly to avoid increased noise?
3 Are sound-absorbing materials used on the ceiling, walls, or machine
covers?
4 Are noisy equipment and noisy parts replaced with quieter models?
5 Are adequate barriers used to prevent noise from spreading?
6 Are workers in noisy work areas rotated to avoid long hours of
exposure?
7 Are earmuffs or earplugs used where the noise level reaches or exceeds
maximum permissible noise level provided by the OSHA (80-90dBA)?
Lighting
8 Is sufficient day light used in the workshop?
9 Are light colors used for walls and ceilings?
10 Is the level of illumination on the weaving point sufficient (minimum
500 lx)?
11 Are the windows and light sources clean?
12 Is harmful direct glare from illumination sources or windows absent?
13 Are the operators eyes free from indirect (reflected) glare?
14 Is the general contrast in the visual field acceptable?
Thermal conditions
15 Is the air temperature suitable for the activity (21 -25C)?
16 Is the humidity suitable (40 - 60%)?
17 Is the air velocity suitable and with no draft?
Air quality
18 Is the air clean and healthy (without airborne contaminants such as
cotton dust, fibers and soil dust)?
19 Is natural ventilation used to improve the indoor climate when needed?
20 Is the workshop regularly cleaned and house kept?

APPENDIX C:
TORNADO INDUTRIAL VENTILATION SYSTEM INSTALLATION PROCEDURE
TableC1: Tornado Industrial roof ventilator installation procedure
1 2 3 4 5 6
Step
Place the base Cut the marked Bend the sheet back at Insert closure at Waterproof base Place the throat
plate onto the roof hole square
the bottom end of the the bottom end of plate using and dome section
and mark the hole with an angle
Description
to be cut grinder cut out and remove base plate and pop silicon or onto the base
closure from under rivet the base plate membrane and plate
ridging onto the roof sealer
Descriptive figure
7 8 9 10 11
ep
St

Make sure that the Adjust throat in order to get the top Fasten the locking Fix the throat If more than one
locking brackets section of the throat and the dome in a brackets onto the base unit is required
are loose level position plate by drilling stagger the units
Description
and using pop across the roof

rivets
Descriptive figure
[source: wind master international; http://www.windmaster.co.za/tornado_tech_info.htm]


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Analyzing the impact of indoor physical work environment on workers performance

BAHIR DAR UNIVERSITY

INDUSTRIAL ENGINEERING PROGRAM

TITLE: ANALYZING THE IMPACT OF INDOOR PHYSICAL WORK

(A case study on Bahir Dar Textile Share Company)

Advisor: Miss. Tirufat Dejene (Msc.)

BAHIR DAR UNIVERSITY

INDUSTRIAL ENGINEERING PROGRAM

TITLE: ANALYZING THE IMPACT OF INDOOR PHYSICAL WORK

(A Case study on Bahir Dar Textile Share Company)

1. Habtamu Tesfaye __________ _______

Student (s) Signature Date

1. _________________________ ___________ ____________

Advisor Signature Date

2. _________________________ ____________ ____________

Undergraduate Project Evaluation Committee Signature Date

3. _________________________ ____________ _____________

School Director Signature Date

BDU, IOT, School of Mechanical and Industrial Engineering Page I

BDU, IOT, School of Mechanical and Industrial Engineering Page II

BDU, IOT, School of Mechanical and Industrial Engineering Page III

BDU, IOT, School of Mechanical and Industrial Engineering Page IV

BDU, IOT, School of Mechanical and Industrial Engineering Page V

BDU, IOT, School of Mechanical and Industrial Engineering Page VI

Fig.1: Organization of the thesis content.5

BDU, IOT, School of Mechanical and Industrial Engineering Page VII

ILO International Labor Organization

BDU, IOT, School of Mechanical and Industrial Engineering Page VIII

BDU, IOT, School of Mechanical and Industrial Engineering Page IX

CHAPTER ONE: INTRODUCTION

1.1 Background of the study

BDU, IOT, School of Mechanical &Industrial Engineering Page 1

1.2 Objectives of the study

The specific objectives of the study are:

1.4 Scope of the thesis and Limitation

BDU, IOT, School of Mechanical &Industrial Engineering Page 3

1.6 Structure and content of the thesis

BDU, IOT, School of Mechanical &Industrial Engineering Page 4

LITEATURE REVIEW ON PHYSICAL

PROBLEM DATA COLLECTION

Fig.1: Organization of the thesis content

BDU, IOT, School of Mechanical &Industrial Engineering Page 5

CHAPTER TWO: LITERATURE REVIEW

Essentially, an elegant and functional workplace environment often culminates in improved

2.2 Work Environment

BDU, IOT, School of Mechanical &Industrial Engineering Page 6

generating an appropriate, adequate, and safe area for work,

An economic benefit sometimes associated with workplace lighting improvements is a reduction

BDU, IOT, School of Mechanical &Industrial Engineering Page 7

Table 2.1: Recommended illumination level

Department/section Illumination level (Lux)

The effects of poor light can include the following:

Signs of visual fatigue are:

Pain full irritation and reddening of eyelids

BDU, IOT, School of Mechanical &Industrial Engineering Page 9

Table 2.2: permissible noise exposures OSHA standards

Duration per day, Sound level dBA slow

BDU, IOT, School of Mechanical &Industrial Engineering Page 10

exposure should be considered to exceed the limit value.

Where: D = noise dose during an 8 hr day;

() = Hours spent at a specified noise level; and

() = Total time of exposure (hours) permitted at that level.

= the noise level at source in decibels; and

1. Habtamu Tesfaye ____ _

1. ___________________ _ ________

2. _____________

3. _____________ _