Systematic ergonomic workplace design in sewing work - Germany

The issue under discussion

The number of work-related diseases and lost working hours has increased in the German sewing industry, mainly due to spine and shoulder/arm disorders. These account for more than 34% of all working days lost in this sector, which is considerably higher than elsewhere.

• Sewing involves highly repetitive movements of the shoulder and arm.
• Static postures of the spine and lower extremities - leaning a long way forwards while sitting - are involved for much of the work.
• The height of many sewing tables is still the same as the foot-operated machines common at the end of the 19th century.
• There is not enough room for the legs between the workbench and foot pedal.

Action taken

The leather industry and textile and clothing professional associations initiated a project aimed at developing an ergonomically designed model sewing workstation and accompanying operational instructions (BGI 804 2). The project, supported by the HVBG, was carried out by the Schwan engineering company in eight sewing companies.

At MEWA, 40 sewing workstations were redesigned according to the BGI 804 2 standard:

• the spatial arrangement of the workspace under the workbench and the foot pedal were altered to encourage an upright working posture and relieve the strain on the spinal column;
• a redesigned foot space with a pedal release enabled the unhindered movement of feet and legs;
• a work table of adjustable height was introduced that can switch easily between sitting and standing;
• adjustable support areas for the hands and arms to reduce the static strain on the shoulders and neck were introduced.

Results achieved

The workers' acceptance of the intervention was high. A clear reduction in strains and stress and increased job satisfaction were reported to MEWA's management. The cost of these measures came to €1,500 per workstation. The overall investment of about €60,000 proved profitable in just a few months: the number of working days lost fell by 16%, the needle operating time for the redesigned machines increased by up to 50% and productivity rose by some 15%.

This approach can be applied directly to other sewing workstations and is transferable to workplaces in other sectors, such as those using assembly workstations.