Keep hand tools from being torture tools

In late March, President Bush repealed OSHA’s ergonomic program standard. Crafted to help employers minimize some of the health problems workers face when doing repetitive manual tasks, critics argued that the rules were far too cumbersome and difficult to enforce.

The now-defunct standard exempted most construction jobs from its regulations. But workers and supervisors are coming to realize how important it is to match the tool to the worker and the work, says Gary VanDuersen, director of innovation and design at Stanley Tool Works.

“In the past, hand tool manufacturers focused more on how to make the tool than how it would be used,” he says, “Today, manufacturers are looking at the total environment in which a tool is used.”

For example, maintaining a neutral hand position is critical. It allows the worker to do a job without irritating muscles and tendons. “The work should be completed with the hand held in as natural of a position as possible,” he says.

If you are doing a certain job that requires you to hold your wrist in an unnatural position, it will eventually cause inflammation. “Change the tool or change the job to help you maintain a good hand position,” he says.

What looks “ergonomic” 
may not be ergonomic at all
Ergonomics does not only consider tool design. Instead, it is the interface of the user with the tool and the tool with the work. Therefore, a tool that is ergonomically correct for one person and one job may be the wrong tool for another person on another job.

“If it looks ergonomic, remain a ‘doubting Thomas’ until you can try it with your work. You’ll see tools with rubber-cushioned grips that look like they would be more comfortable to hold than a conventional rubber-gripped tool, but our research shows that super-soft grips actually increase the amount of force needed to squeeze and transmit power through the tool,” he says.

Similarly, some tools use an innovative-looking angle that can make it better for a specific job, but as an all-around hand tool, actually puts the wrist at risk.

What to look for in tools
Screwdrivers are a great example of how user research has reshaped tools.

“In the past, screwdrivers were designed so they could be made as efficiently as possible. They were basically a round handle with a bit embedded in it.

“When we looked at how users work with screwdrivers, we found that a tri-lobe design with a rounded end fits the hand better and allows the user to exert twice as much torque,” VanDuersen says.

He also suggest users look at the conditions in which they will be using tools. In colder climates, or even on some jobsites where workers must wear gloves, look for handle designs that allow for the extra thickness of gloves.

Tools with handles made with two types of material may help users maintain a better grip.

“We have found that tools with texture strips can help grip. But if the bumps on the texture are too large, it actually can cause pain after extended use. We use the analogy of a bed of nails: Many points of contact bridges the interface and supports the tool grip comfortably.”

The tool evolution continues through pliers. While most rely on a pivot point, Stanley has developed a pliers with a floating pivot that allows the user to exert more of a parallel force on the workpiece. “This is better for the user and better for the workpiece because it offers a more secure grip,” he says.

Published in the May/June 2001 issue of Contractor Tools and Supplies magazine.

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