Snap-on-handles for a non-powered hacksaw: an ergonomics evaluation, redesign and testing

Area of Science:

• Ergonomics
• Human Factors Engineering
• Tool Design

Background:

• Existing non-powered hacksaw handles (original/horizontal and conventional/market) lack ergonomic optimization.
• Hand dimensions vary significantly across male and female populations, necessitating size-specific designs.

Purpose of the Study:

• To propose and evaluate ergonomically designed hacksaw handles tailored to different hand sizes.
• To compare the performance, muscular effort, and user acceptance of new handles against existing designs.

Main Methods:

• Hand dimensions categorized into small, medium, and large for both preferred and non-preferred hands.
• Development of interchangeable, size-specific 'snap-on' handles.
• Comparative testing involving performance (depth of cut), muscular effort (EMG), and subjective comfort scores.

Main Results:

• Ergonomically designed handles showed significant improvements in performance, muscular effort, and comfort compared to conventional and original handles.
• Productivity increased by approximately 25% versus conventional and 148% versus original handles.
• Mismatched handle sizes led to reduced performance, increased muscular effort, and lower comfort ratings.

Conclusions:

• Ergonomically designed hacksaw handles offer substantial benefits in productivity and user well-being.
• Tailoring handle size to individual users is critical for maximizing performance and comfort.
• The 'snap-on' concept facilitates adaptable and user-centered tool design.