5 Hazards in
Industry and Safety
Measures
Introduction
There are different type of machinery that a Sewing
Machine Operator uses in the garment industry. Thus,
it is very important to have an understanding about
the safety and health measures while operating them.
Although it is essential that the management take
important steps to protect and safeguard the operators
from potential hazardous situations, but the best way
for any Sewing Machine Operator to be safe and healthy
is to be aware of the various occupational hazards
associated with sewing machine operation, and work-
related illnesses and injuries. Many of the injuries are
caused mainly by the Operator’s error, carelessness
and inattentiveness.
The Operators must be properly guided for the use
of all the tools and equipment, machines, their safety
measures, and precautions to be taken at the time of
working. It should be compulsory for the Operator to
follow the basic instruction to use machines, tools and
equipment. Suitable furniture, proper ventilation and
lighting and efficient safety measures for emergency
situations are necessary for the safety and health of
the Operators. First-aid kits, safety symbols/signs, fire
extinguishers, and alarms are the most important safety
measures in the manufacturing units.
Unit [Link] 110 17-Mar-21 [Link] PM
Session 1: Risk and Hazards in Industry Notes
Risk is a random incident that may possibly occur, and
if it occurs, it would have a negative impact on achieving
organisational goals.
A hazard is an agent having the potential to cause
harm or hurt to the target. We can call the possible
source of danger as hazard. The terms ‘risk’ and ‘hazard’
are mostly used interchangeably. However, in terms of
risk assessment, they are two very different terms. A
hazard is any agent which can cause harm/damage/
injury to human beings and their environment. Risk is
defined as the probability that exposes one to a hazard
which leads to a negative effect.
All industries have different type of tools, equipment
and machinery. There is always a risk of hazard
while operating machines. They may be physical,
biological, chemical, mechanical, etc. It is crucial for all
operators to be aware of the risk of hazards associated
with the industry they work in. While handling tools
and machines, the Operators should follow safety
instructions. Specialised training must be given to
the Operators to prevent injuries from these hazards.
Operators should take precautions to guard against
work related hazards and accidents.
Most manufacturing units have similar hazards in
their processes and work areas. Hence, it is mandatory
to have adequate equipment and facilities in the unit
to avoid these hazards. Adequate planning, training
and awareness workshops are necessary to train the
Operators, in which they must be made aware of various
hazards associated with their units, and the precautions
to be taken.
All the manufacturing units, whether located
in a commercial or residential area, must comply
and should have the necessary equipment, like fire
extinguishers, hydrants, emergency exits, emergency
lights, hooters, first aids, etc. The Operators may suffer
many occupational accidents due to the processes and
equipment or machines used in the garment industry.
It is the prime responsibility of an organisation to
provide occupational health and safety conditions to
the Operators.
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Notes Type of hazards
In a garment manufacturing unit, all the hazards
mentioned in this session may not be common, but
awareness about various hazards is essential to be
able to deal with them in case they occur. Different
work environments can pose different type of hazards
and risks to the health of the Operators. Therefore,
it is important to identify and address the different
type of hazards with appropriate safety measures, not
only by the employers but also for each individual to
be responsible for the safety and welfare of the self,
all persons working in the organisation as well as the
environment.
There is always a threat to the health and safety
of people at the workplace. These may be chemical
hazards, physical hazards, biological hazards, etc. Here
we have discussed some hazards keeping in mind the
exposure of students of this course towards machines
and industry.
Physical hazards
They often affect many Operators in the workplace, for
example occupational hearing loss, postural defects,
falls, accidents, etc. Hearing loss is one of the most
common problems in a manufacturing unit with heavy
noise-making machines like some industrial sewing
machines or cutters; postural defects like cervical
and bone shape change can occur if a person needs
to sit or stand in a particular wrong position for long
time. Accidents and falls are also a common cause of
occupational injuries and deaths in industries, like
transportation, construction, extraction, healthcare,
building, etc.
Some of the problems associated with the physical
environment at the workplace include:
1. respiratory problems, allergies, skin problem, etc.,
may be caused due to excessive dust. Adequate
ventilation, exhaust fans, etc., are helpful to make
the environment clean and dust-free.
2. a low light environment for working, and shortage
of eye protective glasses, can cause eye problems.
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3. prolonged sitting, and continuous work involving
the eye, creates eye problems (strained eyes) and
backbone problems for the Operators. Repetitive
Strain Injury (RSI) is likely to occur at the workplace
due to long hours of sitting to complete the work.
Problems like backache, stiffening of neck, cervical
and wrist joint problems can also occur during
stitching work.
These problems can be solved with the following tips.
1. Always work with the right body posture.
2. Keep the stand/machines at a height till bust level
and straight wrist position to avoid bending your
neck and back for a long time.
3. Use wrist rests to avoid strain in the hand and
wrist joint.
4. Take short breaks from long sittings, maybe after
an hour or two, to relax the strain in the back.
Fire hazards
They are common in those industries
that use a lot of flammable material, like
cotton, chemicals, etc. Fire hazards occur
mainly due to the following reasons.
1. Improper working of fire and smoke
alarm bells in industries
2. Absence of fire and smoke alarm
systems in many industries
3. Improper maintenance of fire exits
or emergency staircase
4. Lack of proper exit route or
emergency staircase to reach the
place of safety
Every industry should keep fire
extinguishers as a safety measure.
Fig.5.1: Fire extinguishers
Biological hazards
These involve hazards due to bacteria,
viruses and toxins. It can be due to non-
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Notes airy and dark rooms, suffocation (bad ventilation), and
unhygienic conditions of washrooms. These also include
animal bites and stings, problems from toxic plants,
and transmitted diseases through animals.
Chemical hazards
Some chemicals can cause a hazard in the work area.
There are many categories of hazardous chemicals.
Certain chemicals are harmful when mixed with other
chemicals. Chemical hazards are very common in
apparel and textile industry while at the time of dyeing
and printing.
A worker in the garment industry should practise
caution while handling chemicals. The worker must be
made aware of the specific instructions to be followed
while handling a particular chemical.
Psychosocial hazards
This means that the status of mental health and
emotional well-being of the Operators in an organisation
may not be normal. These could be due to a feeling of
job insecurity, long working hours, lack of enthusiasm
towards work, frustration about not being allowed to
deliver quality product due to pressure of quantitative
production, harassment at workplace and poor work-
life balance. This aspect should be dealt with care, as
these are sensitive issues. Behavioural therapy, like
continuous counselling, meditation, yoga, participation
in recreation centres, music therapy or occupational
care are effective in reducing sick leave days and poor
work efficiency at the workplace.
Electrical hazards
These are common in the textile industry as fabrics,
machines and other fire-prone equipment are being
dealt with here. It is quite dangerous when an Operator
creates an electrical contact with keyed up equipment
or a conductor. Electrical accidents mostly occur when
the individuals are working around electrical apparatus
which is live but they think it is dead. Wrong use of
equipment and use of faulty electrical equipment
also causes accidents. Working on, or near electric
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equipment, without adequate training or appropriate Notes
equipment, may be one of the reasons.
Shocks from faulty equipment can lead to brutal and
permanent injuries. Due to serious injuries, the chances
to fall off from ladders or other work platforms are
high. Apart from injuries or accidents, such mistakes
or avoidance lead to damage of the plant, machines,
equipment and property.
To reiterate, it is the role of the management to
provide basic facilities like day care, canteen, rest
room, recreational room, dispensary for first aid, etc.,
so that the Operators focus on their routine work in
the units, uninterrupted. Critical emergency essentials,
such as alarms, evacuation plans, emergency lights
and gathering areas, must be invested in. There is a lot
of machinery used in the garment industry. However,
before any work starts on a machinery, the Operator
should be trained in its proper operations and all safety
precautions should be taken. Proper training and
demonstration of work technique or process is valuable
for each Operator.
Table 5.1: Some Common Hazards and Potential Accidents
and their Preventive Measures
Common hazards Preventive measures
Finger and hand injury The machine must be switched
during cleaning and off, with the plug removed, and
repair work must be stationary before any
cleaning or repair work is started.
Eye injury from broken Proper adjustment of the eye
parts accidentally guard should be checked before
entering the eye work starts. Safety glasses
should be used.
Finger injury from the Setting of the finger guard should
needle be checked before work starts
Injury from tools and Shears and needles should be
equipment of drafting put at the right place after use.
cutting and measuring
tools
Electrical injury Never use a machine with
damaged covers, cables,
switches, etc. Report the damage
at once. Never try to repair it
yourself.
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Notes Internal injury from Never store items temporarily in
accidentally swallowed the mouth. Place needles, etc., in
items suitable containers.
Tripping and falling in the The work area must be clean
surrounding work area and tidy.
Fire hazards: loss of life Place MCB (Motor Circuit
and damage to machinery Breaker), ACB (Air Circuit
due to electric short circuit Breaker), restrict unauthorised
or welding operation person for welding
Practical Exercises
Activity 1
Prepare a chart of the hazards in the garment manufacturing
industry.
Material Required
1. Pen
2. Glue
3. Chart sheet
4. Pictures of hazards related to the garment manufacturing
industry
Procedure
1. Search pictures of various type of hazards in the industry
through the Internet and books.
2. Collect pictures of various type of hazards in the industry.
3. Cut the pictures very neatly with scissors.
4. Paste them on a chart sheet.
5. Label them.
6. Place the chart in classroom/practical lab.
Activity 2
Students will watch a short video on the hazards that occur in
the garment manufacturing industry and the safety measures
that should be taken. Prepare a report of it.
Material Required
1. CD/DVD of short video
2. Internet access for online video
3. CD/DVD player or laptop
4. Projector
5. Screen
6. Seating arrangement for students
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Practical Exercises
Procedure Notes
1. The teacher should arrange to make the students watch a
short video on the hazards in industry and safety measures.
2. The teacher should organise a group discussion regarding
the same.
3. Following the instructions of the teacher, prepare a report
on the hazards in the industry and the safety measures.
Check Your Progress
A. Fill in the blanks
1. Excessive dust can cause respiratory problem,
_____________, skin problem, etc.
2. RSI stands for ____________ ____________ ____________.
3. Biohazards involve contagious bacteria, _____________
and _____________.
B. Find the following words from the maze below
HAZARD, MACHINE, INJURY, ELECTRICAL, ACCIDENT,
ALLERGY, DAMAGE, RISK, HURT
H I N J U R Y A M E
A A S T R A I N A L
C A Z K H U R T C E
C Z D A M A G E H C
I B R L R I S K I T
D M E L G D S C N R
E S H E A R S R E I
N P O R J P K M S C
T Q P G I S S M S A
S R N Y N U V N S L
C. Questions
1. Define the risks and hazards in the garment
manufacturing industry.
2. List out the type of hazards in the garment manufacturing
industry.
3. How can the management reduce the risks and hazards
in the garment manufacturing industry?
4. Write at least two physical hazards that might be faced
by the Operator and give causes and precautions to
avoid them.
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Notes Session 2: Health and Safety Measures for
Sewing Machine Operator
It is always very important for an Operator to be aware of
the hazards associated with sewing machine operations
as many of the injuries are caused by error, carelessness
or inattentiveness on the part of the Operator. The
Sewing Machine Operator should take precautions to
guard against work-related illnesses and injuries. The
Operator must be trained to handle and operate the
sewing machine properly and safely. One should follow
all safety precautions.
Sewing Machine Operators should follow these safety
precautions while working.
1. While sewing always concentrate on the machine
and the task at hand.
2. Always use shields and guards while working with
the open moving parts of machine.
3. Use safety glasses and earplugs while working on
high-speed sewing machinery.
4. Always wear proper footwear to avoid leg and feet
injury. The footwear worn should not slip off from
the feet while operating the machine.
5. Turn off the sewing machine before oiling it or
while changing parts.
6. In the event of a cut wound, or any other injury,
immediately report to the group leader. Wounds
should be cleaned and covered with a bandage.
7. All tools and machinery required for production
should incorporate ergonomic design principles
and should not require an excessive force
to operate.
8. The tools should be easy and comfortable in
holding and using.
9. Work area should be properly designed like enough
space for performing tasks, appropriate working
height and proper sitting arrangement.
10. Improper furniture and poor ergonomic
conditions lead to serious health problems such
as musculoskeletal disorders for example carpal
tunnel syndrome, lower back pain, forearm
tendinitis, neck pain, etc.
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Notes
Fig. 5.2: Operators working on a sewing machine
11. Unpadded stools that may also lack a backrest lead
to the Operators having to sit in an uncomfortable
position without adequate support for the entire
working shift.
12. If there is constant use of pressing irons in sewing
units, the humidity level becomes very high, which
may create discomfort for the Operators.
13. Be provided with short breaks to prevent
muscular pains.
14. Take proper physical rest and mental relaxation in
order to prevent injuries.
15. Adopt an appropriate sitting posture while working.
Avoid working in uncomfortable and awkward
postures.
16. Do not work with hands above the shoulder height
on a regular basis. Arms must be placed at a lower
level and near to the body. Frequent bending and
twisting of wrists, back and neck should also
be avoided.
17. Operators should take proper rest. Give your
muscles rest during the tea/snacks break, lunches
and weekends by doing something different from
what is routine.
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Notes
Fig. 5.3: Sitting position while working on a sewing machine
Good lighting
Proper lighting at the workplace is very essential for
productivity. Conversely, poor lighting can cause eye
strain, fatigue and headache, which results in poor
productivity.
Practices for good lighting
1. There should be an arrangement for proper natural
lighting in the sewing department/unit. This may
help decrease the electricity bill.
2. Work stations that need more light should be
moved closer to the windows.
3. Use a combination of natural and artificial lighting
arrangement, and try to adjust the lighting at the
work area such as, drafting and cutting.
4. The interior colour of the walls affects the
illumination needed. Make sure that the ceilings
should be as close to white as possible. Use pale
colours on walls.
Benefits
1. Good quality of work with less faults and high
production
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2. Decreased tiredness and work-related illnesses, Notes
like itching and strain in the eyes
3. Better health of operators will decrease the number
of sick leaves, and increase productivity
Other things to consider
Many a times, chemicals are used for different
processing in textile and garment industries. Dyes,
solvents and other chemicals are used to create different
fabric finishes. Hence, proper ventilation, respiratory
protection, and other personal protective equipment
should be readily available to protect Operators during
chemical processing.
As a lot of work involves close viewing of the fabric,
material or garment, eye protection is critical. Operators
in the garment industry can avoid eye injuries by using
proper shields on high-speed sewing machinery or
appropriate safety glasses.
Before using any tool or machine, the Operator
should be trained in safe working practices. Some of
the measures are given below.
Safety measures to prevent accidents with scissors
Hand scissors can cause accidents when not used
properly. Scissors injuries usually happen when the
scissors slips during cutting or trimming. In most cases,
the blade cuts the Operator’s hand and/or fingers.
Injuries can also occur to other parts of the body. The
following safety measures should be taken.
1. Use suitable storage system, such as racks, boxes,
etc., near the working area at a comfortable height
to place scissors, blades, etc., after use.
2. Ensure placing lighting fixtures in a way that
the light should fall on the working surface from
the left side or from the front. This promotes
better visibility.
3. Prohibit carrying scissors in pockets, or in the hand
when going from one place of work to another.
4. Do not hold scissors with sharp sides up. Do not
use it when the middle screw is loose.
5. Fix disposal points for used blades.
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Notes 6. Use protective footwear with adequate resistance to
slipping and penetration from a dropped scissors
or other sharp objects.
7. Avoid leaving scissors around the work area. This
can injure both the Operator as well as others
walking around.
8. Provide even floor surfaces with slip resistance so
the operators do not slip.
9. Free the work surface and floor off debris
(pronounced as day-bree) and other waste to avoid
tripping and falling.
Safety measures to prevent accidents with needles
1. Keep needles and pins at a fixed place, such as in
a special box, and all small tools in separate bags
or boxes. Do not leave them at the workplace.
2. Do not hold the needle, pins, etc., in your mouth
or tuck them in the clothes. Do not leave it in
the fabric too. An Operator can sew through
one’s finger.
Safety measures while using spray guns
Spray guns are used to get rid off any stains on the fabric
that may have been transferred while manufacturing.
These guns use a cleaning fluid (many times ethylene)
which may cause headache, dizziness and fatigue if
inhaled, or spirit which can cause redness and excessive
dryness of the skin, if exposed.
Train the Operators in the use of the gun. Spray the
cleaning fluid onto a rag and then use the rag to clean,
rather than spraying on the garment directly.
Safety measures while ironing
1. Practise caution while using a hot iron as it can
cause a major injury.
2. Check for any faults with the cord before using it.
3. Turn on and hold the plug with dry hands.
4. Place the iron only on a heat-resistant stand.
5. Ensure that the cord does not touch the iron
soleplate while ironing.
6. Select an ironing mode (heating temperature)
suitable for the fabric to be ironed.
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Safety and navigation symbols
A signage or symbol is a picture, written word or mark
that represents a message. It is important to know the
different type of symbols used in a workplace so that they
can be followed. There are two type of symbols—safety
symbols and navigation symbols. Safety symbols are
those used for warning and the protection to be taken.
Navigation symbols are used to show the direction or
placement of a certain object or department. Some of
the commonly used symbols are shown in Fig. 5.4.
Symbol for explosives Sign to prohibit flames Sign indicates Hazard symbol
or an explosion hazard and smoking flammable gas for nonflammable gas
Sign for protective Sign for eye protection Symbol for gloves Sign for protective Sign for protective
eyewear required required footwear clothing
Sign for escape route
Sign for ear protection Sign for Symbol for first-aid
required fire extinguisher
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Hazard symbol Hazard symbol for a Symbol for fire exit Hazard symbol for a harmful
for toxic corrosive substance or irritant substance
Hazard symbol for Hazard symbol for Warning sign Symbol for no sitting Sign for fire alarm
flammable oxidising
Fig. 5.4: Safety and navigation symbols
Practical Exercise
Activity 1
Search from the Internet and books, and list out the safety and
navigation symbols used by a Sewing Machine Operator in the
garment industry. Prepare a chart of the same.
Material Required
1. Chart sheet
2. Pictures of safety and navigation symbols
3. Glue
4. Scissors
Procedure
1. Search and collect pictures of safety and navigation
symbols from the Internet and books.
2. Cut the pictures very neatly with scissors.
3. Paste them on a chart sheet.
4. Label them.
5. Display the chart in the classroom/practical lab.
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Check Your Progress Notes
A. Fill in the blanks
1. Operators should wear proper ____________ to avoid leg
and feet injury.
2. Working with improper and insufficient light results in
eye strain, _________ and _______.
3. Operators should take proper physical rest and ________
_______ in order to prevent injuries.
4. Always use ______________ and ____________while
working with open moving parts of machine.
5. Short breaks are necessary to prevent ________________
pain.
6. There are basically two type of symbols — _______________
and _______________.
B. Short answer questions
1. Write a short note on good lighting while working in a
garment manufacturing industry.
2. Write short notes on any five safety practices while
working on sewing machines.
C. Long answer questions
1. Why is it important to take health and safety measures
for a Sewing Machine Operator in the industry?
2. Write about the importance/benefits of good lighting for
the Sewing Machine Operator.
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