Post on 14-Apr-2017
FAMU-FSU COLLEGE OF ENGINEERING
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An Ergonomic Analysis of Full Press Apparel
EIN4243: ErgonomicsNathaly ParedesEmily Singrossi
Brandon Woodall
December 3rd, 2015
Professor John Taylor
FAMU-FSU College of Engineering
2525 Pottsdamer St, Tallahassee, FL 32310
Dear Professor Taylor,
The group is submitting the attached report entitled An Ergonomic Analysis of Full Press Apparel. The start date for the project was September 10, 2015 and ends the 3rd of December 2015.
This report includes an analysis of three different tasked performed at Full Press Apparel Manufacturing Company 3445 Garber Dr, Tallahassee, FL 32303. Each of these tasks is performed in different places around the facility with different tools. Each analysis explains in depth the ergonomic problems that might be compromising the health and productivity of the workers. To better understand the problems and find feasible solutions, multiple analyses were performed. The analysis includes Seated and Standing workstation analysis (Eastman Kodak), RULA analysis, DAMES Model and BRIEF Survey. Additionally, an economic analysis will be performed after examining each of the tasks. This analysis will address financial benefits that will be of advantage for Full Press Apparel.
We would like to give a special thanks to Mr. Daniel Shrine, who was willing to help us since the beginning of this project, for taking the time to explain the team about the machines, and for letting us enter the installations while the employees were working. Additionally, the team would also like to thank the instructor Mr. Taylor since he was the one who taught us how to use the ergonomic analysis necessary in order to fulfill this project, we are sure that this will benefit all team members in our future work experience.
The group hopes this report meets all your requirements and expectations.
Sincerely yours,
Nathaly Paredes (nvp11@my.fsu.edu)
Emily Singrossi (ems11g@my.fsu.edu)
Brandon Woodall (bmw11k@my.fsu.edu)
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Table of Contents
1. Introduction
1.1 Purpose
1.2 Background
2. Discussion
2.1 Heat Press Machine
2.11 Description of the Task
2.1.2 Observations of the Task
2.1.3 Ergonomic Analysis
2.1.4 Evaluation of Alternatives
2.2 T-Shirt Transfer Process
2.2.1 Description of the Task
2.1.2 Observations of the Task
2.1.3 Ergonomic Analysis
2.2.4 Evaluation of Alternatives
2.3 T-Shirt Folding Process
2.3.1 Description of the Task
2.3.2 Observations of the Task
2.3.3 Ergonomic Analysis
2.3.4 Evaluation of Alternatives
2.4 Economic Analysis and Conclusion
3. References
Appendix
Appendix 1. Worker printing a design in the Heat Press Machine
Appendix 2. Standing vs Seated Workstation for the Hand Press Machine
(Eastman Kodak)
Appendix 3. Rapid Upper Limb Assessment for the Hand Press Machine
Appendix 4. T-Shirt Folding Workstation
Appendix 5. Standing and Sitting Spine Curvature
Appendix 6. The BRIEF Survey used to show a task’s risk rating
Appendix 7. The ergonomic issues of the T-Shirt Transition process
Appendix 8. DAMES Process for T-shirt folding workstation design
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Executive Summary
An Ergonomic Analysis Report is intended to examine different tasks performed
at Full Press Apparel, which is a company located in Tallahassee, Florida. at Full
Press Apparel, a retail and production company located in Tallahassee, Florida.
Full Press Apparel has 40 workers tasked with customizing T-shirt orders through
screen printing, embroidery, and design.
The three tasks that the team will analyze include the operation of the heat press
machine, the T-shirt transfer process, and the T-shirt folding process. These
tasks are different from each other, and they are performed in different places
around the facility using different machines.
Full Press Apparel employees range over multiple demographics. One important
factor in our task analysis is that we must consider that the workstations should
be able to fit all types of populations accounting for height, gender, and several
other factors that can affect the work performed. Additionally, ergonomic tools
such as the RULA analysis, Standing Workstation Criteria Checklist, DAMES
Model, and BRIEF Survey will be performed along the report in order to find what
improvements can be made in the workplace to diminish fatigue, and increase
productivity in the workplace.
Relevant conclusions and results will be discussed along with the solutions
related to each ergonomic problem encountered. In addition, an economic
analysis is also included to determine the cost of implementing the solutions
found by the team.
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Introduction
1.1 Purpose
This projects aims to identify processes that involves a significant amount of
manual labor and determine what improvements can be made to provide a more
comfortable, safer, productive, and efficient working environment. Team
members will observe, analyze and propose solutions of several tasks by
applying the knowledge and tools acquired in their Ergonomics class. Moreover,
this analysis will assist the team in suggesting better workstation designs and
appropriate guidelines for how the work should be done in order to improve
ergonomics.
1.2 Background
Founded in 1997 by Daniel Shrine, Full Press Apparel helps meet Tallahassee’s
high collegiate demand for custom t-shirts and promotional items. Full Press
Apparel is known for transforming creative ideas into reality. It is a primary
supplier of custom screen-printing and embroidered apparel. However, through a
deep commitment to family, community service and product excellence, Daniel
has grown to serve businesses, associations, state agencies and non-profit
organizations in addition to numerous colleges and universities across the
country.
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2. Discussion
2.1 Heat Press Machine
2.1.1 Description of the Task
In this task, an operator stands and folds one shirt at a time. Then the worker
places each shirt individually on the machine’s surface. The platen is then
lowered and pressed onto the machine’s surface to be printed. This task requires
pressure from the workers hand, heat from the machine, and precision work
when printing the design in the desired location. The worker will apply pressure
to the machine in 10-second intervals by repeating the same movement with their
hands and wrists for an 8-hour shift. This task image is attached in Appendix 1.
2.1.2 Observation of the task
By observing the worker perform the task, the team noticed the several
ergonomic issues that must be taken into account.
Buttons: The steaming button is too far from the workers reach. This leads to
awkward torso postures by bending and reaching to grasp the buttons.
No Job Rotation: One worker will perform the same task for 8 hours, which
engages highly repetitive motions of the wrists and hands every 10 to 15
seconds.
Repetition and Precision Required: Modify workstation to provide the option
for employees to sit, stand or lean when doing their task.
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2.1.3 Ergonomic Analysis:
A RULA analysis and a Standing vs Seated Workstation Criteria were performed.
Team members used the “Appropriate Conditions for Standing/Sit-Stand/Seated
Workstations” by Eastman Kodak to determine the appropriate workstation for
this task. According to Kodak, the workplace standing characteristics are:
frequent movements between steps are necessary, forward reach below the seat
pan, sufficient clearance, and the use of feet is not required. On the other hand,
the workplace seated position characteristics are: task requires visual attention;
the object weighs less than 10 lbs., downward forces are not required, and the
task doesn’t require handling heights above the work surface. Appendix 2 was
used to determine if the workstation dimensions are appropriate. The table height
and reaching distance from the workers location to the platen did not align with
the seated checklist. The work requires precision and a table height of 40-50”;
however, the actual height was 36”. Also, the ideal beginning working distance
and optimum work area are 1-4” and 10”x10”, respectively. The actual beginning
distance and work area are 8” and 18”x7.5”, respectively. Appendix 3 uses a
RULA analysis to evaluate the upper limb extremity ergonomic risk factors
associated with the task. By performing the RULA the team rated the task a five,
meaning further investigation is required and changes might be needed soon.
2.1.4 Evaluation of Alternatives
Considering both analyses performed, the team evaluated that the best
alternative is to purchase an adjustable chair for the worker to perform the task,
and to rotate between tasks since performing the same wrist movement
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repetitively might lead to Musculoskeletal Disorders. According to Eastman
Kodak Conditions, a worker should be seated when doing tasks that require
visual attention, since there’s no job rotation, the task is performed for more than
5 minutes repeatedly and that the platen weights less than 10 lbs. Moreover, if
the worker is of shorter stature, the operator won´t be able to reach the platen
leading to awkward body movements.
2.2 T-Shirt Transition Process
2.2.1 Description of the Task
This process involves two machines and two operators. Two operators handle
the Automated Press Machine (APM) and part of the shirt drying oven. The APM
has eight protruding ‘shirt sized’ platforms that rotate in a circular motion via
operator command. During the rotation, a screen suspended above the platform
presses and prints on the shirts on the platform. One operator picks up a shirt to
print a design, then it is slide onto the platform of the machine through the middle
of the shirt. The shirt is now flat on a protruding platforms. The other operator is
removing a completed shirt off the protruding platform and twisting around to
properly place it on the oven behind him. The original operator, at its own
digression, commands the APM to press and rotate the shirt. The process
continues until the order is complete. The second operator also works with a
different employee to tend to the oven, this is a separate task from the T-Shirt
transition process and will not be included in the ergonomic analysis.
2.2.2 Observation of the Task
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The team observed the task for a few minutes to identify the number of T-shirts
produced. The number of T-shirts produced is equal to the number of tasks
needing ergonomic improvement, which was greater than two a minute. After
observing the task, the team identified a few possible ergonomic issues identified
in Appendix 7 below.
Back Bending: The operator bends over to flatten the shirt on the machine
each time the shirt needs preparation for the mechanical press. This process
is constant until the order is complete which, over time, effects the neck
position as well.
Wrist Rotation: When a shirt is transferred onto the machine, precision is
required to ensure the shirt is in the proper pressing position.
Back Twist and Reach: The operator transfers the shirt from the machine to
the oven directly behind them in a twisting motion. During the transfer to the
oven behind the operator, the operator must place the shirt in the proper
position on the oven. This position causes some operators to reach across
the oven to properly set the shirt.
Communication: Verbal communication is rarely used during the task
process.
Small Working Quarters: The process consists of many steps, each which
involve movement. The oven is directly behind the machine which leaves
room for a few steps rather than an entire walking motion.
2.2.3 Ergonomic Analysis:
To first identify the top ergonomic opportunities, the team used the BRIEF survey
method shown in Appendix 6. An operator’s neck, back and elbows had the
highest risk rating when compared to the other body parts analyzed. To eliminate
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these ergonomic risks, the team focused on what causes the back bends and
twist, elbow extension and neck bends. After speaking to the operators, the team
identified the first operator’s task as precision work. The shirt needed to be
specifically placed to ensure the image printed was properly aligned with the shirt
center and pocket. This means the APM workstation needs to stand at 40
inches, according to the North American male minimum workstation height
requirement. However, the APM inadequately stands at 37 inches, which causes
the risky back/neck bends and full elbow extension. The operator hunches over
to align the T-shirt, bending his back and neck over 20 degrees. The increase in
angle forces his elbows to fully extend their 135 degrees.
The T-shirt transition process expects the operators to move freely amongst one
another when completing tasks. A second operator has an issue moving freely
and cannot access the proper T-shirt placement on the oven rack. When the first
operator is bent over he takes up more space than when he stands straight.
Operator two, then, twists to place the T-shirt in the smaller workspace. A larger
workspace area would eliminate an operator’s need to twist his back.
2.2.4 Evaluation of Alternatives and Solution Development
Based on Eastman Kodak the team determined a set of possible solution based
on the seated/standing workstations and machine alteration justification. An
operator performing precision work is typically best preformed seated; however,
the job workplace characteristics require an operator to stand. In the T-Shirt
transition process, a downward force above 10 pounds is required to imprint the
screen on the T-shirt, frequent forward reaches above 14.8” are required when
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pulling down the screen, and frequent movement between workstations is
required. These outweigh the suggested seated condition for precision work.
Justification of the operator standing helps validate the need to raise and move
the machine. The team recommends to raise the APM to 50 inches and move it
two feet away from the oven. This raise is based off North American standards,
the maximum value for all demographics. In order to ensure all operators can
reach the machine, the team recommends having a portable step stool near the
APM.
2.3 T-Shirt Folding Process
2.3.1 Description of the Task
The T-shirt folding process uses a standing workstation that is typically occupied
by one to two workers based on the amount of T-shirts produced during that shift.
At this station, the shirts are exiting the oven from the T-shirt transition process
on a conveyor belt. The shirts are then picked up off the conveyor and moved to
one of two tables that are positioned perpendicular to the end of the conveyor
belt; however, if a shirt is not grabbed off the conveyor in time, the shirt is
dumped into a bin that is placed on the ground beneath it. The two tables are
located were the shirts are folded then placed into their respective piles based on
the shirts size and style. From there the piles of shirts are placed into boxes
where they are then prepped for shipping. An illustration of this workstation can
be seen in Appendix 4.
2.3.2 Observation of the Task
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After analyzing the two employees work in this process for several minutes, there
were a few observations made that can affect the ergonomic efficiency of the
workstation, which can be seen in Appendix 4 and are bulleted below.
Seated or Standing Workstation: The current work area requires the
employees to stand throughout their shift, however the workstation is large
enough to support one or two mobile chairs for the employees to work from.
Shirt Bin Placed on the Floor: Shirts not removed from the conveyor in time
are dropped into a collection bin that is placed on the floor. Continuously
bending over to pick up these shirts from the bin can cause excessive stress
on the employee’s backs.
Light Work: The process of grabbing the shirts, folding and placing them into
a pile is considered light work and does not constitute as precision.
Height of Employees Varies Drastically: Two employees working in the folding
area varied in height by over 10 inches. This must be accounted for designing
workstation that has to accommodate both the shorter and taller employees.
2.3.3 Ergonomic Analysis:
For this task the DAMES process was used to perform a workstation design
analysis, this process is illustrated in Appendix 8. The primary focus was to
decide whether or not to make a standing or seated workstation. Standing for
long periods of time curves the lower back forward, a condition called Lordosis.
Sitting down curves the back in the other direction, a condition called Kyphosis.
These two conditions can be seen in Appendix 5.
Again, the goal is to reduce stress on the back, therefore recommendations for
both seated and standing workstations were made to decide which is more
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ergonomically safe. Since the work is classified as “light work,” the recommended
table height should range from 35.2” to 44.9” for a standing workstation to
accommodate both small females and large males in North America, according
to the Ergonomic Design Guidelines for Engineers. For a seated workstation the
recommended table height is 21” to 34”. It is also recommended that work be
done from 1” to 14” from the edge of the table to avoid excessive leaning and
bending of the back. Purchasing an adjustable table that can rise or sink to the
height range is recommended for this workstation. Lastly, it is recommended that
the height of the collection bin be raised to a minimum height of 24” off the
ground to reduce the amount of bending over to retrieve the shirts out of it.
2.3.4 Evaluation of Alternatives
All the recommendations made for the workstation design are efficient in making
the work safe from an ergonomic standpoint; however, since the work requires a
lot of travel between tables, conveyor belt, bin etc. and the does not require
precision, a standing workstation is more ideal for this process. Along with being
a standing workstation, the use of an adjustable table between the heights of
35.2” and 44.9” is strongly recommended since there is such a large difference in
heights of the employees. The final design recommendation is to place blocks or
a platform beneath the collection bin to a minimum height of 24” to reduce the
stress of back bending to lower heights
2.4 Economic Analysis and Conclusion
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According to the analysis performed at Full Press Apparel the team concluded
different recommended solutions for:
Task 1: The components that will be needed are an adjustable chair and to rotate
job between workers. Selecting an adjustable office chair costs ranges from
$169.00 to $450.00 (“Chairs & Seating at Office Depot and OfficeMax”). Full
Press Apparel has 40 employees, it would be optimal to select one of those
workers and rotate between tasks.
Task 2: Full Press Apparel will need to budget for moving the machine. This cost
will be neglected because one less operator will need to complete this task.
Assuming salary is minimally $31,200 a year, Full Press will benefit from a
tradeoff of contracting the manufacturer at less than the operator’s annual salary.
Task 3: The components that will be needed are an adjustable table based on
results. Adjustable tables range from $479 to $1449 based on the sizes and
quality of the tables (“Adjustable Tables Office Depot and Office Max”)
Usually the direct cost per year per individual patient with musculoskeletal
disorders has increased nearly 61% between the years 2009 to 2011, rising from
just over $4,800 to nearly $7,800 per person (Yelin). For shifts with a large
product demand, fatigue can set in quickly with the repetitive motions of
grabbing, reaching, bending, folding and placing the shirts. Long term effects of
continuous strain on the back caused from poor posture can lead to severe spine
disorders such as Lordosis, Kyphosis and Scoliosis. Therefore, the total cost for
implementing these solutions will be less expensive than handling a medical bill.
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References
“Adjustable Tables Office Depot and Office Max”. Adjustable Tables at
Office Depot and Office Max. N.p..n.d. Web 27 Nov. 2015.
"Chairs & Seating at Office Depot and Office Max." Chairs & Seating at
Office Depot and Office Max. N.p., n.d. Web. 27 Nov. 2015.
“Workstation Heights and Distances” Ergonomic Design Guidelines for
Engineers. N.p., n.d. Web. 1 Dec. 2015.
Yelin, Edward. "Chairs & Seating at Office Depot and OfficeMax." Chairs
& Seating at Office Depot and OfficeMax. N.p., n.d. Web. 27 Nov. 2015.
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Appendix
Appendix 1 : Worker printing a design in the Heat Press Machine
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Appendix 2. Standing vs Seated Workstation for the Hand Press Machine
(Eastman Kodak)
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Appendix 3. Rapid Upper Limb Assessment for the Hand Press Machine
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Appendix 4: T-Shirt Folding Workstation
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Appendix 5. Standing and Sitting Spine Curvature
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Appendix 6. The BRIEF Survey used to show the highest risk rating, two, during the T-Shirt transition task
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Appendix 7. The ergonomic issues of the T-Shirt Transition process
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Appendix 8. DAMES Process for T-shirt folding workstation design
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