Mr Henning, one of your recent development projects focused on improving ergonomics in automotive final assembly, specifically by reducing high insertion forces when installing cable clips. What was the initial challenge that triggered this work?
One of the main challenges we identified on final assembly lines was the consistently high push-in forces required when installing cable clips. At one OEM site, operators were fitting large volumes of clips per shift and often had to apply forces exceeding 70 Newtons. This kind of repeated strain was leading to an increase in hand and finger injuries, more sick leave, and rising retraining costs. It quickly became clear that we needed to rethink our fastening solutions with a stronger focus on both ergonomics and economic impact.
What did the customer ask for and how did that shape your approach?
The customer set a clear benchmark: push-in forces should stay below 30 Newtons, while pull-out forces had to remain above 110 Newtons. This applied to a wide range of fixings: fir trees, edge clips, weld studs. That spec guided everything we did. But it wasn’t just about hitting the numbers. It was about making life easier for operators while keeping the part secure.
We didn’t stop at meeting the target of max. 30 N push-in and 110 N pull-out forces – in fact, we exceeded them significantly. In some cases, we reached push-in forces as low as 5 N while achieving pull-out strengths of well over 150 N. Another tested design achieved below 15 N push-in and over 200 N pull-out force. These improvements mark a substantial leap in ergonomic performance – far beyond the original goal.
So what solutions did HellermannTyton develop?
We’ve made a series of targeted improvements to support safer and more efficient installation. One example is our latest fir tree designs. They maintain the required holding strength but significantly reduce the push-in force, helping to lower the strain on operators’ hands. That’s now our new ergonomic benchmark. We also redesigned our weld stud clips to meet a 30 Newton insertion force target while still delivering over 110 Newtons in pull-out strength. Another great example are our EdgeClip solutions: they offer tool-free fastening that saves a lot of time.
Beyond meeting technical targets, how important is the topic of ergonomics in your view?
It is absolutely essential. Ergonomics is no longer just a side note or a nice-to-have. It is directly linked to employee health, long-term productivity and the overall performance of a production line. When we reduce physical strain through better product design, we help lower the risk of injuries, minimize downtime and avoid retraining costs. But more than that, we contribute to creating safer, more respectful workplaces. That has a lasting value for both the people and the business.
This sounds like a cross-functional effort. Who else was involved in the project?
It really was global collaboration at its best, built on close teamwork across sites, time zones and areas of expertise. From the very beginning, we worked side by side with the customer’s ergonomics and engineering teams. Internally, the core development was led by our Swedish design team in close coordination with colleagues in Germany. This strong partnership between the Swedish and German teams was key to aligning fast-paced design iterations with thorough testing and validation.
Further support came from our teams in China and the U.S., who contributed material expertise and testing capacity. Credit goes to Scott Adams, who developed the new fir tree design, and to Christoph Cords and his team for their work on improving the edge clip. Marten Otterstrom from the Swedish design team deserves particular recognition for developing the clip that achieved a maximum 5 N push-in force and well over 150 N pull-out strength – a major leap forward in ergonomic performance.
It is a clear example of how we combine our international strengths to deliver results that make a real difference.
What impact did you see in production?
On one of the customer's high-volume production lines, we were able to reduce average push-in forces from around 70 Newtons to just 30 Newtons. That result has become the new benchmark. Moving forward, only ergonomic fastening solutions that meet this standard are approved for use at that site. For us, that’s not a challenge – it’s a standard we already meet. And for the operators on the line, it means noticeably less strain, reduced risk of injury and better long-term health.
Finally, what does this say about how HellermannTyton works with customers?
It is a strong example of how we work. We do not just respond to specifications. We listen, we anticipate and we co-develop. Our goal is to create solutions that fit smoothly into our customers’ systems and support their long-term strategies. When our parts are added to their approved component list, it shows that they trust us. That trust motivates us to keep improving.
Thank you for the interview, Patrik, and all the best as you continue to push the boundaries of ergonomic design.
