Johnson & Johnson

Attune Pin Jack: Function and Ergonomic Balance

2011  |  Design Lead

Attune Primary Total Knee Replacement System is regarded as one of the most advanced joint replacement solutions in the world.

One of the system's instruments, a pin installer and remover, was one of the most challenging devices to design because of its frequency of use and various hand positions across the procedure. I led the research and design of this instrument.

REDESIGNING THE PIN PULLER

The Attune Primary Total Knee Replacement System is composed of over 600 individual instruments, varying from implant trials to spacers to knee jigs and screw drivers. Out of all of these instruments, one of the most frequently used across a knee procedure was a simple pin puller.

Pins (nail-like instruments), are used across the system for positioning and fixation. Pins serve both as reference points as well as ensuring a device was mounted correctly. Traditionally, the name "Pin Puller" was given to the instrument that removed pins throughout the procedure even though the instrument would also help place the pins as well.

Last minute critical feedback from our surgeon team required a new design. With tremendous pressure to deliver a new product quickly before launch, the team asked me to lead the design effort since I had designed several of the other instruments in the system.

My DESIGN PROCESS included:

A. A review of current pin pullers we have across every system I could find

B. A thorough competitive analysis of pin pullers across the industry, including customer feedback from surgeons on the team

C. And finally, a rigorous design and test cycle that involved numerous rapid prototypes and several phases of research and testing.

After these initial phases, we had enough information to compare them to our anthropometric data standards and apply our human factors considerations. The focus was on the span of the device, the amount of force required to perform operations as well as multiple hand holding positions across the procedure.

IDEATION

After pulling together all the research and testing, I sketched a few concepts that took into account the human factors requirements. Reviewing the designs with the wider team allowed me to focus on the top ideas to model and prototype for evaluation by our surgeon design team.

HF SUMMARY

Below is the final summary from my design sprint including my recommendations and considerations with the final design direction.

FINAL DESIGN

This is the final design of the device, which we renamed to Pin Jack because of its dual purpose. Currently, it is included in every award-winning Attune Total Knee Replacement System (Primary & Revision).

https://www.depuysynthes.com/patients/knee/attune-knee

https://www.depuysynthes.com/hcp/knee/products/qs/ATTUNE-Revision-Knee-System