Hand tool mechanisms designed to reduce the risk factors have rarely been studied. In this paper it is analyze trowel firstly designing in CATIA and then its Finite Element Analysis has been carried out by ABAQUS. The main emphasis is on finding stresses by using this software, then removing them by suitable mechanical working on tool & ergonomic change in the design of handle to make it more comfortable. Body part discomfort score and overall discomfort rating experienced by the subjects had

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... so been estimated. During the muscular activity workers physiological responses i.e. energy expenditure rate, oxygen consumption rate and heart rate increases. This increase in physiological responses is related to the type, intensity and duration of work and thus sets limits to the performance of heavy work. In this paper oxygen consumption rate and heart rate was used for physiological cost estimation. These parameters were measured by Computerized Ambulatory Metabolic Measurement System K4b 2 .