Styling vs. solutions

Truly ergonomic hand and power 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 and other tools.

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

Then what makes an ergonomic hand or power tool indeed ergonomic?

That, too, is open to interpretation and debate.

Manufacturers are not held to a true regulation, guideline or standard in developing or marketing tools 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, North American product manager for Sandvik Saws and Tools Co., Scranton, Pa. “There is a growing danger of confusing cosmetic styling with true ergonomics.”

Are you selling styling or solutions? And if you sell the latter, how do you impress that upon a customer who may be confused about ergonomic branding?

Give him or her the facts, figures and findings.

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 $15 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 causes 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
Salespeople need to inform customers 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 products and product redesigns.

“You 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 for certain circumstances and situations. 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 North Carolina State and the University of Connecticut.

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

Companies like Sandvik and Atlas Copco 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, product 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 salespeople and distributor salespeople to get as much feedback as possible from operators. Their responses help manufacturers refine products.

“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, 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.

Stanley Works 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 are using these tools,” says van Deursen.

Beyond the tool
As OSHA’s Stephens and the majority of tool companies stress, tool design is only a piece of the puzzle. It’s how the tool is used and the work environment that the tool and operators are subjected to that can trigger stress, strain and injuries.

“You have to take the entire picture into consideration,” says Dynabrade’s Mandell. “You have to 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 workbench is too high, the job has people lying on their back or using the tool above shoulder height, there are going to be problems.”

While some companies send ergonomists to plants to detect trouble spots, most rely on the eyes, ears and training of salespeople and distributor salespeople.

Radwin says salespeople, especially those visiting the plant, need to be educated on ergonomics.

“There are a lot of training courses on ergonomics that are offered around the country. They need to attend some if they haven’t already,” he says. “The other thing is asking the customer and the people that use the tools a lot of questions.”

See what ails them and try to come up with a cure.

The two major goals of ergonomics are a more effective workplace and improved work conditions. Helping a customer realize these goals can mean improved productivity, fewer errors, greater safety and less stress for his or her company. It can also mean added sales for you.

This article originally appeared in the March/April '99 issue of Progressive Distributor. Copyright 1999.

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