TORO - Ergonomic Study

Brief

Redesign an existing product to better suit real-world ergonomic conditions, using the Indian anthropometric chart as a reference rather than the manufacturer's original (US-based) sizing assumptions. The Toro Recycler 22" — a basic 149cc home-lawn grass cutter — was chosen as the subject.

Process

We started by physically using the mower and mapping its touchpoints: the deck-height adjustment, the brake lever, the recoil pull-start, and the handlebar grip. Each interaction was tested against a spread of body sizes to catch where the design held up and where it didn't.

That testing surfaced a consistent set of friction points:

• The handlebar surface wasn't comfortable to hold for long mowing sessions
• The handle height and angle worked for an average user but not across the full percentile range
• The reach to the recoil start was awkward for shorter users
• Adjusting deck height and swapping the grass bag both required more effort than they should

Design Response

From there, we sketched and iterated on handlebar geometry — testing quick-release joints, telescoping sections, and rotating grips to find a shape that could adjust across users rather than fit only one.

The final concept:

• Adjustable-height handlebar, with the joint where the handle meets the deck redesigned to flex for different percentile groups
• Reshaped grip surface for better comfort over extended use
• Larger recoil wheel, which shortened the recoil-start wire and made the pull-start easier to reach

Validation

Every change was tested with a rig — the same setup used to record 5th, 50th, and 95th-percentile users interacting with both the original and redesigned mower — to confirm the new geometry actually improved reach and posture across the range, not just for one body type.

Outcome

The point where the handle meets the deck now flexes across percentile groups, the handlebar is comfortable for extended use, and the shorter recoil wire (enabled by the larger wheel) makes starting the engine easier for a wider range of users.