MRO Today - Ergonomics: Styling vs. solutions

Styling vs. solutions
Truly ergonomic hand tools and powered hand tools
are the product of research, testing and feedback.
But the tool can only go so far.

by Paul V. Arnold

What is ergonomics?

It might sound like an easy question, but page through the catalogs of tool manufacturers and read the definitions used to preface their lines of ergonomic screwdrivers, saws, wrenches, drills, sanders, etc.

It doesn't take long to realize no two definitions are exactly alike.

Then what makes an ergonomic hand tool or powered hand tool indeed ergonomic? That, too, is open to interpretation, and debate.

Manufacturers are not held to a true regulation, guideline or standard in the development or marketing of a tool branded as ergonomic.

No scientific data needs to be gathered in order to earn that label.
So, a company can research, test and refine the look, feel and composition of its hammer and call it ergonomic. And a company can simply change the color of its hammer handle from black to optic orange and call it ergonomic.

"There are a number of companies that jump on that term as a marketing ploy because in the consumer's mind, ergonomics stands for high quality," says Mark Weigel, a product manager for Bahco Tools. "There is a growing danger of confusing cosmetic styling with true ergonomics."

Are you buying styling or solutions? Do your homework and find out.

Facts and figures
According to the Occupational Safety and Health Administration, ergonomics is the science of fitting the job to the worker. When there is a mismatch between the physical requirements of the job and the physical capacity of the worker, that worker's body is at risk.

Musculoskeletal disorders (which include cumulative trauma disorders, repetitive strain injuries and overuse injuries) are the No. 1 occupational hazard in the American workplace and cost employers more than $10 billion a year in compensation claims.

"If a company has incidences of these disorders, it needs to have a program with many components to address the problems," says Roger Stephens, the director of OSHA's Office of Ergonomic Support.

"One part of that program is tool selection. You need a good match between the tools and the tasks and the people doing the tasks."

Over the past decade, most tool manufacturers have spent time, energy and capital focusing on the cause and effect of tool-related musculoskeletal disorders.

They've listened to end-users and examined ways to refine products and better meet worker needs.

They've turned problems or potential problems into solutions.

Some examples:
Problem: Pistol-grip drills provide excess strain on the trigger finger.
Solution: Lengthen the trigger so it's clenched by several fingers.

Problem: The vibration from grinders and hammers initiate poor hand circulation, as well as numbness and tingling.
Solution: Cover housings with shock-absorbing materials and select core materials for handles that reduce shock and vibration.

Problem: Pneumatic tools can transfer cold air to the operator's hand and lead to Raynaud's Syndrome, also known as "whitefinger" disease.
Solution: Create handle coatings that provide insulation and protection.

"Industrial tool users are becoming aware of the benefits of ergonomics in hand and power tools and are demanding that their suppliers provide tools that address their concerns," says Rob Radwin, a professor of industrial engineering at the University of Wisconsin and the director of the school's Industrial Hand Tool and Ergonomics Research Consortium. "Most manufacturers are responding to those tool users' needs."

Backing up the claims
Prior to buying an "ergonomically designed" tool, end-users need to ask their supplier about the tool maker's research and testing practices, and their efforts to educate consumers on ergonomics. Practices such as these provide the backbone for ergonomic claims and products.

The Wisconsin research consortium is one way manufacturers are taking the initiative. Ten tool manufacturers help fund the program. In return, they receive research data they can incorporate into new and redesigned products.

"They need to back up the claim by indicating the research that makes it ergonomic," says Radwin. "The research we do tries to develop guidelines and establish parameters for the design of tools. We focus on design and the way a tool is used or should be used."

Tool makers also fund ergonomics research at schools such as the University of Connecticut and North Carolina State.

Many companies that fund university projects also have internal programs that study ergonomics at the laboratory and field levels.

Some companies have ergonomists on staff that provide input for product design, information for consumer literature and workplace assessments.

"Our ergonomist heads an ergonomics committee, and nothing leaves the drawing board or becomes a prototype unless it passes that committee," says Dan Grippo, marketing manager for Atlas Copco. "When it gets into the prototype stage, it again has to pass the committee."

When a prototype or finished product is put on the assembly line,
companies rely on their outside representatives and distributor representatives to get as much feedback as possible from operators.

Responses are used to refine or alter the product.

"If operators say the handle isn't comfortable, we'll look at that and make changes," says Andrew Mandell, assistant marketing manager for Dynabrade.

Stanley Works has a two-pronged approach to research and testing.

"We have an ergonomics lab in the design department where we can come up with an idea and then test it, modify it, on and on, until we get something that is visibly, measurably better," says Gary van Deursen, the company's director of industrial tool design.

It also has "Discovery Teams" that travel the country and explore tool usage in the workplace.

"These guys are out every day, taking early prototypes, later prototypes, production pieces and putting them in the hands of workers," says van Deursen. "We get significant feedback."

Team members also photograph the tools being used on the line or in the maintenance department.

"We have an extensive file of how these people are really using these tools, as opposed to three engineers thinking they know how people use these tools," he says.

Beyond the tool
As stressed by OSHA's Stephens and tool companies, tool design is only a piece of the puzzle. It's how the tool is used and the work environment that the tool and operator is subjected to that can trigger stress, strain and injuries.

"You have to take the entire picture into consideration," says Dynabrade's Mandell. "Take a close look at the workstation and work environment and job task. The tool can be comfortable, but if the lighting is poor, the work bench is too high, the job has people lying on their back or using the tool above shoulder height, there are going to be problems."

The major goals of ergonomics are a more effective workplace and improved work conditions. Realizing these goals can mean improved productivity, fewer errors, greater safety and less stress. It also creates happier employees.

SIDEBAR

Ergonomic tool rules
CooperTools provides these basic guidelines for tool selection and usage.
* The tool should function effectively. For example, a pair of tin snips should easily cut thin sheet metal without the need for excessive force.
* The tool should fit the operator. Not only should the tool fit a user's hand properly, but it should also match the operator's work
capacity and skill.
* The tool shouldn't produce fatigue.
* The tool should provide sensory feedback. You should be able to sense pressure, impact, texture, etc.
* Smooth cylinders are generally not the best shape for most tool
handles.
* Avoid form-fitting handles (handles with ridges to fit the fingers).
* Handle materials should provide enough friction for an adequate grip.

This article appeared in the August/September 2000 issue of MRO Today magazine. Copyright, 2000.