When sealing an application with a radial O-ring system design there is a balance between O-ring function and ease of assembly. Often times the assembly insertion force rises to the point of unacceptable manufacturing ergonomic practice. Designs are released into production with these high insertion forces while manufacturing operators struggle to assemble parts leaving opportunity for potential operator injury. Several variables impacting O-ring system insertion forces were tested to quantify the effects. Results were analyzed to identify design controls that could be implemented from an early design phase optimizing functionality and ease of assembly.