Redesign of Workspace Through an Ergo-Lean Model to Reduce Musculoskeletal Disorders in SMEs In the Clothing Accessories Sector

Redesign of Workspace Through an ErgoLean Model to Reduce Musculoskeletal Disorders in SMEs In the Clothing Accessories Sector
  IJETT-book-cover           
  
© 2021 by IJETT Journal
Volume-69 Issue-12
Year of Publication : 2021
Authors : J.C. Quiroz, D.M. Aquino, E.A. Rodriguez, M.F. Montoya
DOI :  10.14445/22315381/IJETT-V69I12P219

How to Cite?

J.C. Quiroz, D.M. Aquino, E.A. Rodriguez, M.F. Montoya, "Redesign of Workspace Through an ErgoLean Model to Reduce Musculoskeletal Disorders in SMEs In the Clothing Accessories Sector," International Journal of Engineering Trends and Technology, vol. 69, no. 12, pp. 163-174, 2021. Crossref, https://doi.org/10.14445/22315381/IJETT-V69I12P219

Abstract
Currently, the textile and clothing industry contributes 2% to the global annual GDP and generates more than 57 million jobs worldwide. In South America, a country with a high market share in the textile sector in Peru, whose industry is the objective of this research due to its lack of studies in the accessory sector of clothing. Musculoskeletal disorders are the most common and leading cause of injury and disability in workers and in the clothing industry; it is due to the handling of materials that involve machinery with a high rate of repetition of work by operators. This article aims to reduce the percentage of Musculoskeletal Disorders (MSDs) by redesigning workstations and using combined ergonomic tools together with Lean tools so that, in addition to giving focus to workers, a different way can be found to add value to the process and improve productivity. A 71.85% decrease in MSDs was achieved in the sewing and cutting area, as well as a decrease in absenteeism by 20.73%, along with savings of S /. 505.72 per year.

Keywords
Clothing, Ergonomics, Lean, Musculoskeletal Disorders, Workspace.

Reference
[1] M. F. Fadillah and E. Muslim, Ergonomic evaluation in a screen-printing division of a garment small-medium enterprise (SME) using the posture evaluation index in a virtual environment, in AIP Conference Proceedings, 2193(1) (2019) 050006, doi: 10.1063/1.5139379.
[2] Link Compresores, Panorama de la industria textil en Colombia y América Latina para 2020 - Link Compresores, (2020). https://www.linkcompresores.com.co/panorama-de-la-industria-textil-en-colombia-y-america-latina-para-2020/ (accessed May 16, 2021).
[3] Textiles Panamericanos, La Industria Textil en América Latina | Textiles Panamericanos, (2021). https://textilespanamericanos.com/textiles-panamericanos/2021/04/la-industria-textil-en-america-latina/ (accessed May 16, 2021).
[4] PRODUCE, Estadística Sectorial, (2020). https://ogeiee.produce.gob.pe/index.php/en/shortcode/estadistica-oee/estadistica-sectorial (accessed May 16, 2021).
[5] BCRPData, PBI (variación porcentual), (2021). https://estadisticas.bcrp.gob.pe/estadisticas/series/anuales/resultados/PM04863AA/html/2015/2021/ (accessed May 16, 2021).
[6] D. Carhuavilca et al., Panorama de la Economía Peruana, (2020). Accessed: May 16, 2021. [Online]. Available: https://www.inei.gob.pe/media/MenuRecursivo/publicaciones_digitales/Est/Lib1726/Libro.pdf.
[7] ADEX, CADENA TEXTIL-CONFECCIONES AYUDARÁ A REACTIVAR LA ECONOMÍA, (2020). https://www.adexperu.org.pe/notadeprensa/cadena-textil-confecciones-ayudara-a-reactivar-la-economia/ (accessed May 16, 2021).
[8] G. Segar, M. Nasrull, and A. Rahman, Musculoskeletal symptoms and ergonomic risk assessment among production operators at manufacturing industries: A review, (2019), doi: 10.1088/1757-899X/607/1/012009.
[9] D. Alves Da Silva, Z. De Oliveira Silvano, J. Aparecida, and C. De Souza, Ergonomic Analysis of the Work in a Garment Industry in Laranjal-Minas Gerais, Int. J. Eng. Trends Technol., 64(2) (2018), Accessed: Nov. 08, 2021. [Online]. Available: http://www.ijettjournal.org.
[10] L. Mathew, Influence of Job Stress on Musculoskeletal Disorders Among Employees in Construction Industries in Kerala, Int. J. Eng. Trends Technol., 17(8) (2014), Accessed: Nov. 12, 2021. [Online]. Available: http://www.ijettjournal.org.
[11] W. F. Stewart, J. A. Ricci, E. Chee, D. Morganstein, and R. Lipton, Lost Productive Time and Cost Due to Common Pain Conditions in the US Workforce, J. Am. Med. Assoc., 290(18) (2003) 2443–2454, doi: 10.1001/jama.290.18.2443.
[12] S. Kumar, P. #1, and V. Somkuwar, An Ergonomics Study of Four Wheel Vehicles: A Review Paper, Int. J. Eng. Trends Technol., 43(1) (2017), Accessed: Nov. 11, 2021. [Online]. Available: http://www.ijettjournal.org.
[13] I. Hoque, P. Hasle, and M. M. Maalouf, Lean meeting buyer’s expectations, enhanced supplier productivity and compliance capabilities in the garment industry, Int. J. Product. Perform. Manag., 69(7) (2020) 1475–1494, doi: 10.1108/IJPPM-08-2019-0410.
[14] G. H. Biadgo, G. S. Tsegay, S. A. Mohammednur, and B. F. Gebremeskel, Burden of Neck Pain and Associated Factors Among Sewing Machine Operators of Garment Factories in Mekelle City, Northern Part of Ethiopia, 2018, A Cross-Sectional Study, Saf. Health Work, 12(1) (2021) 51–56, doi: 10.1016/j.shaw.2020.10.002.
[15] M. D. Hossain et al., Prevalence of work-related musculoskeletal disorders (WMSDs) and ergonomic risk assessment among readymade garment workers of Bangladesh: A cross-sectional study, PLoS One, 13(7) (2018) 3, doi: 10.1371/journal.pone.0200122.
[16] B. Suhardi, E. Juwita, and R. D. Astuti, Facility layout improvement in sewing department with Systematic Layout planning and ergonomics approach, Cogent Eng., 6(1) (2019), doi: 10.1080/23311916.2019.1597412.
[17] R. Lima, L. Fontes, P. Arezes, and M. Carvalho, Ergonomics, Anthropometrics, and Kinetic Evaluation of Gait: A Case Study, Procedia Manuf., 3 (2015) 4370–4376, doi: 10.1016/j.promfg.2015.07.433.
[18] C. Bontrup et al., Low back pain and its relationship with sitting behavior among sedentary office workers, Appl. Ergon., 81 (2019) 102894, doi: 10.1016/j.apergo.2019.102894.
[19] A. Colim et al., Lean manufacturing and ergonomics integration: Defining productivity and wellbeing indicators in a human-robot workstation, Sustain., 13(4) (2021) 1–21, doi: 10.3390/su13041931.
[20] M. Brito, M. Vale, J. Leão, L. P. Ferreira, F. J. G. Silva, and M. A. Gonçalves, Lean and Ergonomics decision support tool assessment in a plastic packaging company, in Procedia Manufacturing, 51 (2020) 613–619, doi: 10.1016/j.promfg.2020.10.086.
[21] A. R. Mohammed, M. O. Mohamed, Y. A. Alhubaishy, K. A. Nasser, and I. S. Fahim, Ergonomic analysis of a working posture in the steel industry in Egypt using digital human modeling, SN Appl. Sci., 2(12) (2020) 1–8, doi: 10.1007/s42452-020-03872-y.
[22] A. Mehdizadeh, A. Vinel, Q. Hu, M. C. Schall, S. Gallagher, and R. F. Sesek, Job rotation and work-related musculoskeletal disorders: a fatigue-failure perspective, Ergonomics, 63(4) (2020) 461–476, doi: 10.1080/00140139.2020.1717644.
[23] S. Teixeira França, Z. De Oliveira Silvano, J. Aparecida, and C. De Souza, Work`s Ergonomic Analysis of the Production Sector of a Plastic Bag Factory in Cataguases/ Minas Gerais, Int. J. Eng. Trends Technol., 64(2) (2018), Accessed: Nov. 10, 2021. [Online]. Available: http://www.ijettjournal.org.
[24] A. ur Rehman, M. B. Ramzan, M. Shafiq, A. Rasheed, M. S. Naeem, and M. M. Savino, Productivity Improvement Through Time Study Approach: A Case Study from an Apparel Manufacturing Industry of Pakistan, Procedia Manuf., 39 (2019) 1447–1454, doi: 10.1016/j.promfg.2020.01.306.
[25] M. Montoya-Reyes, A. González-Angeles, I. Mendoza-Muñoz, M. Gil-Samaniego-Ramos, and J. Ling-López, Method engineering to increase labor productivity and eliminate downtime, J. Ind. Eng. Manag., 13(2) (2020) 321–331, doi: 10.3926/jiem.3047.
[26] W. Susihono, - Ariesca, and L. Lady, Implementation of the Ergonomic-Based Standard Operating Procedures (SOP) in Reducing Postural Stress Complaints, Work Fatigue and in Increasing the Employee Income, Company Profits in Manufacturing Industry, Int. J. Adv. Sci. Eng. Inf. Technol., 11(1) (2021) 150, doi: 10.18517/ijaseit.11.1.11046.
[27] A. C. Alves, A. C. Ferreira, L. C. Maia, C. P. Leão, and P. Carneiro, A symbiotic relationship between Lean Production and Ergonomics: insights from Industrial Engineering final year projects, Int. J. Ind. Eng. Manag., 10(4) (2019) 243–256, doi: 10.24867/IJIEM-2019-4-244.
[28] H. Silvano dos Santos and Z. de Oliveira Silvano, Ergonomic Analysis of Call Center Work In A Company In City of Cataguases, Int. J. Eng. Trends Technol., 67 (2019) 11, Accessed: Nov. 08, 2021. [Online]. Available: http://www.ijettjournal.org.
[29] A. M. Eladly, M. G. Abou-Ali, A. M. Sheta, and S. H. EL-Ghlomy, A flexible ergonomic redesign of the sewing machine workstation, Res. J. Text. Appar., 24(3) (2020) 245–265, doi: 10.1108/RJTA-10-2019-0050.
[30] B. Abdel Aziz MAH and M. Arm, LEAN MANUFACTURING SYSTEM AND ITS IMPACTS ON WORK ENVIRONMENT AND HUMAN HEALTH IN GARMENTS MANUFACTURING, (2017).
[31] V. Kulkarni and C. Kapali, Ergonomics Study for Injection Moulding Section using RULA and REBA Techniques in Production management at BVBCET HUBLI KARNATAKA INDIA 2 Assistant Professor Department of IPE, BVBCET HUBLI KARNATAKA INDIA 3 Student, M Tech in Production management at BVB, Int. J. Eng. Trends Technol., 36(6) (2016), Accessed: Nov. 10, 2021. [Online]. Available: http://www.ijettjournal.org.
[32] J. Baca, F. Sánchez, P. Castro, E. Marcelo, and J. C. Alvarez, Productivity Improvement In Companies of A Wooden Furniture Cluster In Peru, Int. J. Eng. Trends Technol., 69 (2021) 97–107, doi: 10.14445/22315381/IJETT-V69I10P213.
[33] Y. K. Cham, E. L. M. S. #2, C. F. Yeong, S. N. Z. Ahmmad, S. Sood, and A. Gandhi, Physical Factors Investigation on Surgical Dexterity Parameters Using Computer-based Assessment System, Int. J. Eng. Trends Technol., 69 (2021) 27–33, doi: 10.14445/22315381/IJETT-V69I4P205.
[34] M. Cathoud De Barros Chagas, T. Bittencourt Nazaré, and A. E. Oliveira, Time and Movement Analysis in shell Molding Process, Int. J. Eng. Trends Technol., 67 (2019) 11, Accessed: Nov. 12, 2021. [Online]. Available: http://www.ijettjournal.org.
[35] K. Erliana, F. Kautsar, … D. O.-… on E. and, and undefined 2019, Solving Office Ergonomics Problem Using Rapid Upper Limb Assessment (RULA), atlantis-press.com, (2019), Accessed: Oct. 23, 2021. [Online]. Available: https://www.atlantis-press.com/article/125921249.pdf.
[36] C. S. García, A. C. Marroquín, I. A. Macassi, and J. C. Alvarez, Application of working method and ergonomic to optimize the packaging process in an asparagus industry, Int. J. Eng. Trends Technol., vol. 69(9) (2021) 14–23, doi: 10.14445/22315381/IJETT-V69I9P202.
[37] M. M. Cremasco, A. Giustetto, F. Caffaro, A. Colantoni, E. Cavallo, and S. Grigolato, Risk Assessment for Musculoskeletal Disorders in Forestry: A Comparison between RULA and REBA in the Manual Feeding of a Wood-Chipper, Int. J. Environ. Res. Public Heal. 16(5) (2019) 793, doi: 10.3390/IJERPH16050793.
[38] L. N. Chanca Valverde and R. J. Salinas Díaz, Modelo para reducir el ausentismo mediante el rediseño de puestos de trabajo en industrias de artículos escolares del sector plástico, Univ. Peru. Ciencias (2021), Accessed: Oct. 23, 2021. [Online]. Available: https://repositorioacademico.upc.edu.pe/handle/10757/657550.
[39] OIT, Seguridad y salud en el trabajo (Seguridad y salud en el trabajo), Organización Internacional del trabajo, (2021). https://www.ilo.org/global/topics/safety-and-health-at-work/lang--es/index.htm (accessed Oct. 23, 2021).