SAFETY IN GARMENT INDUSTRIES

The Garment Industry is generally seen as a safe place to work. Compared to other industries, there are relatively few serious accidents in cloth producing plants. The hazards we face are different. The major health risks in this industry do not arise from immediate, potentially fatal hazards. Instead, the risks that clothing workers face come from more subtle hazards whose effect accumulates over time. Research shows that sewing machine operators face a substantially higher risk of muscle pain and injury than workers in other jobs. Studies also show that the frequency of persistent neck and shoulder injuries increases with years of employment. One report found that sewing machine operators experience as many cases of repetitive strain injuries as data entry operators and secretaries combined. These injuries lead to long-term health effects. This is why we wanted to look at the working conditions that can lead to such high rates of disability for Garment Industry workers. Another most common findings is poor housekeeping i.e. untidiness, disorder and clutter not only reduces productivity by blocking the smooth flow of materials through the industry, it often represents a fire hazard as boxes, thread, trimmings and other combustible materials are left everywhere. The two recent fire accidents occurred in our neighboring countries indicate that unplanned work environment, disorganized workers, electric short circuit, faulty electrical wiring, smoking materials, boiler explosion, kitchen stove and carelessness could anytime lead to producing charred human bodies instead of clothing of various kinds out of the Garment Industry. Fire that broke out in Ali Enterprises, a Garment Factory in Karachis Baldia Town on September 11, 2012 killed over 250 workers and another mishap at Tazreen Fashions in Bangladeshs capital Dacca on November 24, 2012 charred 112 workers mostly the weaker gender. More importantly, industry management were found to be totally unaware of the need and importance of the means of escape, the fire exit route to escape from the affected area to a place of safety or a place of refuge in case of fire. The humidity of the air may influence the health and comfort of the worker as too dry air can cause local irritation of mucosa, eyes and skin. The overall symptoms are dizziness and headache. In the case of too humid air, the sensitiveness to the odors (gases, vapor) from the finishing materials will increase. Most workplaces have a number of different hazards, which can be divided into the following broad categories namely mechanical, physical, chemical, ergonomic and psychosocial. Of course, these hazards are common to many occupations and workers are often exposed to more than one at a time. For example, it is not difficult to imagine a worker in a garment industry being in a hot, noisy environment and using an unguarded machine. With the worker feeling tired and losing concentration in such an environment, there is the potential for an accident if any guards are missing off the machines. Workers do not create hazards in many cases; the hazards are built into the workplace. It is essential that work is made safer and healthier by modifying the workplace and all unsafe work processes. To get a very clear picture of the status of safety to be ensured in the Garment Industry, well discuss the aforesaid mechanical, physical, chemical, ergonomic and psychosocial hazards.

I) MECHANICAL HAZARDS 1. Fencing off machinery: Many serious accidents at work involve machinery and occur for several reasons, including: Badly designed machine guards (e.g. those that can be removed); Poor maintenance of machines and guards; Guards are not provided; No supervisory system to ensure that guards are used; Payment/bonus systems that encourage shortcuts (e.g. guards can be removed if they restrict production); Lack of adequate training for workers on the safe use of machines. There are three basic parts of a machine that must be guarded: A. The point of operation the actual point where the work is performed on the material, such as cutting or sewing; B. The power transmission apparatus all components of the mechanical system that transmit energy to the part of the machine performing the work. These components include flywheels, pulleys, belts, connecting rods, couplings, cams, spindles, chains, cranks, and gears; C. Other moving parts all parts of the machine which move while the machine is working. These can include reciprocating, rotating, and transverse moving parts, as well as feeder mechanisms and auxiliary parts of the machine. Machine guards are essential for protecting workers from needless and preventable injuries (see figure below). A good rule of thumb to remember is that any machine part, function, or process which may cause injury must be guarded. Where the operation of a machine, or accidental contact with it, can injure the operator or other workers in the immediate area, the machine must be guarded.

All too often workers can get caught in unguarded machinery and can be fatal.

The most common accidents in the garment industry tend to be: Cut fingers for machine operators in the cutting section; A needle in the finger of sewers; Burns from irons in the ironing section; (This information is available from looking at the accident record book. A close analysis of these records can help you to identify priority areas that need to be addressed as a matter of urgency). As with all machinery, the machines in the garment industry are potentially dangerous. The most obvious are probably the band knives in the cutting section (see picture below).

A typical picture from the cutting section. It is essential that the adjustable guard is in place and the operator has been given the appropriate training to use the machine. The worker is wearing PPE a dust mask and chain-mail gloves. One problem often encountered is that the chain-mail gloves are too big with the ends dangling near the blade. With gloves that are too large, workers lose control and accuracy. If you take a walk-through survey of a garment factory, one of the most common observations is the number of machines that have guards missing or that the guards are inadequate. As has been stipulated in the Factories Act 1948, it is important that you purchase so-called safe machines with fixed guards as an integral part guards that cannot be removed, that allow for safe maintenance, and that provide clear visibility.

2. Use safe lifting procedures: Avoid lifting objects that are too heavy. Use more than one person or a mechanical device to reduce the load. Your workstation should not require you to lift objects above your head or twist your back while lifting. Keep the load close to your body and ensure that you have a good grip. Heavy and frequently lifted objects should be stored between knee and shoulder height not on the ground or above your head.

Tool Box Talk is a discussion held between all members of a lifting operation prior to the commencement of the work in order to agree on all aspects of the particular work and the sequential steps to be performed to complete the work safely without any harm to anybody or damage to any art of the lifting machine, lifting accessories and materials. Historically, companies have used toolbox talks to discuss with employees subjects ranging from production, to quality, operating procedures, engineering plans, project status, human resource issues, and company policy. In the present context toolbox talks, alternatively termed toolbox topics, safety chats, safety briefings, or tailgate meetings have been used extensively by the construction and oil industries4, and increasingly by other sectors including the facilities, and chemical and allied process industries as regular, short (530 minutes) informal ways of educating the workforce on specific Safety, Health and Environment (SHE) topics. They are used internationally to varying degrees. For example, the contents of the Tool Box Talk for Manual Handling of materials may extend beyond the following guidelines: Know your capabilities; only tackle lifts you can handle. Can you handle the load yourself, do you need assistance? Is there a clear walkway with good lighting to the work area? Checks that should be carried out before lifting: Always check you know the weight of the load before lifting. Wear gloves to protect against cuts and punctures:

wear safety boots or shoes to protect from falling loads. Carry out a trial lift by rocking the load from side to side, and then try lifting it a small amount to get a feel for it.

Stand close to the object and keep your feet apart to maintain your balance.

Make sure that you grip the load with your palms and not your fingers. All lifting equipment and lifting accessories must be subjected to a thorough examination scheme and in-service inspections to ensure continued mechanical integrity. The personnel undertaking the lifting operation should also visually examine the lifting equipment and lifting accessories before and after performing the lift looking for any obvious defects (Pre- and Post-use Checks).

2. Keep pressure vessels safe: If pressure equipment fails in use, it can seriously injure or kill people nearby and cause serious damage to property. In the daily operation of cloth producing plant, pressure vessels in the form of boilers, pressurized piping, steam heating plants and air compressors are being used. Hence overpressure can happen due to incidents like a blocked discharge, fire exposure, tube rupture, check valve failure, thermal expansion that can happen at process heat exchanger, and the failures can occur. This can lead to a major incident in plant if the pressure relief system is not in place or not functional. Designed pressure relieving devices should be certified and approved under Code1. ASME- Boiler and Pressure Vessel Code Section I, Power Boilers, and Section VIII, Pressure Vessels and 2. BIS 2825:1969. As stipulated in the Boilers Act 1923 and the Factories Act 1948, the boilers and pressure vessels in service shall be periodically examined respectively and the results of such test and examination shall be kept readily available for inspection of the concerned authorities. The boilers and pressure vessels shall be in the charges of the competent persons who have been exclusively trained for the purpose. 4. Use appropriate Hand Tools: Sewing machine operators frequently use several tools such as scissors or knives and occasionally hammer. Large, heavy scissors are used for trimming threads and are held by the blade to provide accuracy. Operators cut through several layers of fabric with scissors that are too small and do not provide enough leverage. Scissor handles are narrow and create contact stresses. Scissors are dull and require excessive force to operate.

Appropriate Tools

Inappropriate Tool that can catch fingers Operators should have appropriate scissors for the task such as small, light clippers or a finger cutter to trim thread, and long scissors that provide leverage for cutting through several layers of fabric. Knives for removing seams should have a small blade and a large comfortable handle. A dead blow hammer is better when operators must use a hammer to flatten seams.

2)

PHYSICAL HAZARDS
The work environment includes all the parameters such as lighting, noise, vibration, electricity, temperature and humidity. The lighting levels ranged from 176 918 lux with a mean of 410 lux. According to the provisions laid down in the Factories Act 1948, the lighting between 500 lux and 1000 lux gives satisfaction to workers. The noise level in the cloth producing industries ranged from 74 dBA to102 dBA with mean of 91.7 dBA. In India, the current threshold level value for eight hour noise exposure is 85 dBA. Hence the noise level in the garment industries was found to be above the recommended levels. High noise levels are found in some parts of garment industries. For example, if the factory has associated generator sheds and boiler houses, these machines are likely to produce noise levels well in excess of what is considered safe. Similarly, if many of the sewing machines are old or mounted incorrectly, they are likely to produce high noise levels. The health effects of noisy environment and presence of vibration are temporary and permanent hearing loss and vibration disease called vibration white finger. This condition results from persistent microscopic damage to nerves and tiny blood vessels in the hands and fingers as a result of long-term exposure to vibration.

Burns, electric shock or sometimes death may be possible due to frayed wiring, broken plug sockets and wires dangling close to workers in many parts of a garment industry. Due to danger of electrocution there is possibility of fire. Many garment workers complained of hot, humid conditions in key sections of the garment industry such as ironing area. The other health effects reported were irritability, heat cramps, exhaustion and stroke (dehydration). As a result, some owners provided ad-hoc solutions by placing fans in certain locations to try to increase the ventilation. Prolonged exposure to cotton dust, flax and soft hemp can lead to the chronic respiratory disease known as byssinosis characterized by wheezing, chest tightness and a shortage of breath amongst the affected workers (particularly noticeable after the weekend break and therefore called as Monday Fever). This is probably due to a histamine releasing substance. In addition to histamine release, exposure to cotton dust causes irritation in the upper respiratory tracts and bronchi, which after prolonged exposures slowly progresses to chronic obstructive pulmonary disease. Besides all garment industries have dust problems. Dust fibers mainly produced from cutting and sewing sections of garment industries can be seen on workbenches, lamps and even workers hair. The smallest of these fibers are breathed in by the workers and, over the long term, cause a variety of respiratory problems. The problems are made worse as many industries use brooms and dusters to clean the workplace rather than use of industrial vacuum cleaners which simply spreads the dust and dust control is often made worse as workers do not wear their dust masks in the correct fashion.

3) CHEMICAL HAZARDS
From the perspective of the garment industry, the main chemical problem come from the high dust levels in certain sections of the industry (e.g. the cutting section) and from the choice of chemicals used in the spot cleaning process. The Fire Hazard Properties of the Flammable Chemical, Naphtha, V.M. &P, are recorded here for ready reference: N.F.P.A./OSHA Class IB liquid Flash Point = 280F (-20C) Flammable Limits = 0.9 to 6.0 % by volume Specific Gravity = < 1 Hazard Identification Diamond Rating: Fire = 3 & Health = 1 Water soluble = No The cleansing fluid used in the course of the manufacturing process is having severe fire hazard as well as minimal health hazard. As such every effort shall be taken to avert the possible release of chemical vapor into the working atmosphere. General Guidelines for the Storage of Flammable Chemical: DO store bulk Naphtha, V.M.& P, in suitable smaller containers on drip trays that have 110% capacity of the largest container; DO store fuels and oils away from drains and water courses;

DO replace lids on containers after use; and DO not use damage or leaky containers.

4)

ERGONOMICAL HAZARDS

A well-designed workstation is important for productive work. Most garment workers repeat the same or similar tasks throughout each shift, which, if performed efficiently and quickly, can result in greater productivity. Further, each workstation should be designed to suit the needs of the individual worker (dependant upon height, reach, size, etc) and take into account the type of machine being used and the task being performed. Lower back problems are on the increase as more workers sit at their workstations all day. Often, workers are provided with simple benches with no backrest. A well-designed chair is essential one that is adjustable for individual workers, for the height of the worktable and task, and that provides full lower back support. The chair should allow workers to lean forward and backwards easily. The worker should have adequate leg room under the worktable so that he/she can change the position of the legs easily. The feet should be flat on the floor or the worker should be provided with a footrest this will eliminate pressure on the thighs and knees. Many garment workers stand all day at their workstation. Standing for long periods on hard concrete floors, often in bare feet, can cause back pain, sore feet and tired muscles. If a job must be done in a standing position, a chair or stool should be provided for the worker so that he/she can sit down at regular intervals. A non-slip mat on the floor cushions the strain on joints, legs and back. The mat can be put on top of a platform in the case of high benches and short workers. At this juncture, it is quite purposeful to remember that for most of the industrial workers, the ultimate profit they get out of their employment is the fatal injury to their occupational health principally from two causes. The first and most potent is the toxic and other harmful materials they handle in the course of their employment..the second cause more evidently is the violent and irregular motions as well as unnatural work postures of their body, by reason of which the natural structure of the vital human machine is so impaired that serious diseases are gradually develops there from. In order to decrease fatigue, it is advisable to provide a rest pause that is 10 minutes followed by every 50 minutes of work.

5)

PSYCHOSOCIAL HAZARDS
Factors responsible for psychosocial illness are frustration due to type of work, risks involved in work, monotony, long working hours, lack of recognition, lack of job

satisfaction, poor man/woman management, lack of welfare activities and tensions at home and place of work. Work-related stress is not an illness but it can lead to physical effects such as heart disease and gastrointestinal disturbances leading to ulcers and psychological effects such as anxiety and depression. The indicators for psychosocial group are chronic absenteeism, mass leave, lock outs, strikes and unexplained reduction in production. Unhygienic latrines and urinals, sub-standard canteens and but prevalence of overcrowding, sexual harassment, discrimination in wage fixation, not enough maternity leave, no baby care center, etc. have led to psychosocial disorders then and there. The medium and small sized garment industries are found to have poor illumination, improper ventilation, excessive noise, congested work area, unergonomic workstations. The workers were exposed to dust, chemicals mainly in the form of solvents, ergonomical problems, psychosocial problems, etc. Due to lack of education, unawareness of the hazards of their occupations, general backwardness in sanitation, poor nutrition and climatic proneness of this geographic region to epidemics aggravates their health hazards from work environment. Hence, measures towards improving the awareness of occupational health and safety and thereby motivating the workers in use of personal protective equipments would help in achieving a safe and healthy workplace environment.

A Clean, bright and airy canteen in a Garment Factory.