When is light work heavy? Components of the physical workload of sewing machine operators working at piecework rates

Epidemiologists have associated the job of sewing machine operators with a high incidence of musculoskeletal and other health problems, despite its classifications as light work according to energy expenditure criteria. An ergonomic analysis was undertaken in a trouser factory in order to describe components of the physical load of this work: force exerted, repetitions, time allocation and postures. Work activity of ten operators was observed and timed in situ, and forces were measured with a dynamometer. The time required to sew one seam is very short, 10-15 s per trouser leg. This short cycle is repeated more than 1500 times during the work day, involving quasi-continuous movements of the same parts of the body. The fact that movements are repeated so many times means that small details of the task assume a great importance. During the work day, a substantial force is exerted, only part of which can be measured with current technology. By these measurements, operators lift an average 406.1 kg of trousers per day and exert an average total force of 2858.4 kg with the upper limbs and 24 267.9 kg with the lower limbs. The work posture is static: seated with upper back curved and head bent over the sewing machine. Movements of the upper limbs involve abduction and adduction of the shoulders while exerting a force. For the same task, there is considerable variation in the dimensions of workstations. Interviews were conducted to determine the types of musculoskeletal complaints. The components of work activity could be treated to these complaints and to existing epidemiological data on musculoskeletal problems among sewing machine operators. This type of detailed examination can be applied by health and safety personnel to identify task components which could be changed to minimize the probability of musculoskeletal problems.