Automotive

Fasteners may be small, but their impact on vehicle safety, assembly efficiency, and worker well-being is quite large. In this Q&A, Michael Murray, product line manager at fastener and assembly solutions supplier ARaymond, talks about the core role that ergonomics play as new fastener innovations are developed — with the goal of achieving quicker installation and fewer worker injuries, and better outcomes for everyone from the assembly line operator to the automaker.

Why is ergonomics such an important focus in the design and development of fasteners, and what are the benefits?

I oversee the development of new fastening solutions for a wide range of automotive applications, with a strong focus on ergonomics and operator experience. Talking about ergonomics is really talking about care. We must consider the person who’s actually going to assemble the parts. At ARaymond, we believe in taking a human-centric, empathetic approach. We want to think about the person who will be installing a part hundreds of times a day – how we can make their job safer, easier, and less physically demanding. If we ignore that, we risk injuries, turnover, and a less engaged workforce.

Better ergonomics leads to fewer injuries, faster install times, and lower costs for suppliers and OEMs alike, while also boosting morale and fostering a sense of pride on the assembly line. Workers are more confident when they know the tools and parts they use are designed with their health in mind. For manufacturers, shorter assembly lines mean more vehicles rolling off the line in less time. It's a win for everyone – delivering reduced assembly time, increased vehicle safety, minimising strain on operators, and reducing operational costs for suppliers and OEMs.

From a manufacturing perspective, what are some common ergonomic challenges workers face with traditional fasteners?

Cyclic loading – or operators doing the same motion repeatedly – can result in long-term injury, fatigue, or even hospitalisation. Sharp edges can lead to cuts and when a fastener is hard to install or poorly designed, it not only slows things down but also affects morale. Small parts, installed in large volumes, can add up to a big problem.

Traditional fasteners have featured nuts and bolts, and ARaymond has been focused on moving to more clip-based fastener solutions. Beyond simply embracing clipping solutions in the fastener industry, ARaymond is also paying close attention to factors like torque load, ease of handling, and visibility in tight spaces to improve how these clips are manipulated on the assembly line. Ergonomic design must consider much more than just how a clip goes in.

Can you walk us through some ergonomic improvements ARaymond has made to its air bag clips?

One development that stands out is our recent breakthrough in passive safety fastening systems – specifically, our new generation airbag clip. We've rapidly gained traction in the North American market, engaging directly with leading Tier 1 safety system suppliers and some of the largest OEMs in the industry. This is not just incremental progress – it’s a foundational shift in how airbag modules are secured, designed for easy alignment, smoother insertion, and significantly less torque, while maintaining the same high level of safety and retention.

How have these redesigned clips improved the installation process on the line?

The impact has been immediate and measurable. We’ve reduced installation time by a minimum of 5 seconds per fastening location. That’s 1 to 3 minute time savings at the very first assembly station alone.

From an ergonomic perspective, we’ve engineered the clip to install with 20N of insertion force – down from an industry norm of 45N. That’s a 55% reduction in physical effort required per install, dramatically lowering fatigue and risk of strain injuries, especially over repetitive cycles. We also refined the clip’s footprint for easier visual alignment and hand placement, which is critical in low-visibility or tight-access areas.

We also embedded a compact threaded element into the clip architecture – for faster torque application, and to replicate the tactile feedback and familiarity of a traditional nut and bolt interface. This enables detection features that confirm proper installation – a crucial quality assurance measure in passive safety systems.

The results speak for themselves: streamlined installs, reduced ergonomic burden, improved precision, and a ripple effect of efficiency across the entire assembly line. It’s a convergence of human-centric design and technical rigour – exactly where we believe the future of fastening innovation lies."

How do these improvements contribute to vehicle safety?

Air bags are among the most critical safety components in a vehicle. The moment they’re called upon, everything needs to function with absolute precision. Coming from an active safety background, I’ve brought that same precision and attention to detail to this project. Our team on this project has ensured the clip is fully tested, highly reliable, and 100% detectable. It’s not just about making the part easier to install; it’s about ensuring it stays put and performs when it matters most, when an airbag must be deployed. The ergonomics are important – but ultimately, this is about performance under pressure.

How does ARaymond approach ergonomic innovation across the product line?

Ergonomics is a topic that is always on our minds, no matter what fastener we’re working on at ARaymond. Our work process on the airbag clips is just one example of this. It’s not just about solving problems – it’s about shifting perspective. When ergonomics becomes part of the design DNA, you start to see opportunities to improve the assembly experience in places you wouldn’t have looked before. That’s how we’re evolving the role of the fastener – one thoughtful, human-centered innovation at a time.

Are there any upcoming projects or trends in ergonomics you're excited about?

Every day brings a new challenge – and that’s what makes this field so exciting. OEMs and process engineers are constantly raising the bar on ergonomic expectations, and that continuous pressure is what fuels meaningful innovation. As industry standards evolve, so must our solutions. I think we’ll continue to see fasteners that are not only safer and easier to install, but also smarter in how they integrate into the assembly line. ARaymond has always been on the leading edge of fastening technology – and our job is to keep pushing that edge, delivering ergonomic and intelligent solutions that add real value on the line and in the vehicle.

Ultimately, we want to make fasteners that are easy to install, provide feedback to the operator, and retain securely to protect lives. That’s a big ask – but when we get it right, it has a ripple effect across the value chain. Better products lead to better operators and better vehicles.