The use of a personal protective device (ppd) is a widely accepted method of safeguarding workers from occupational hazards in industrialized countries (IC) and an important method employed in developing countries (DC). Though protection is assured if the devices are worn constantly, it is unfortunate that due to discomfort and inconvenience, the majority of those exposed to hazards do not wear them. DCs which mainly import ppds from ICs are confronting many ergonomics problems, because the equipment designed for IC conditions is inappropriate for use in DCs, due to significant differences in user body sizes, environments and working methods. A questionnaire survey conducted among ppd manufacturers in 11 ICs revealed that 90% followed standards in manufacturing. Another survey conducted among health and safety authorities who responded on behalf of ppd users in 35 DCs revealed that the most common ergonomic causes of non-use are stresses from hotness, weight, improper fit and obstruction at work. While manufacturers place greater emphasis in the protection performance of the equipment, users in DCs refuse to wear it because the comfort needs are not fulfilled. Developing ergonomics standards for ppds seems to be a feasible way of persuading the manufacturers to provide ergonomic values in ppds. The need for maximum allowable comfort in the design, taking into consideration the user characteristics and protection factor is emphasized. To overcome the inherent discomforts that are extremely difficult to reduce without compromising the protection efficiency of a ppd, the principle of user adaptation seems to be a very important facet which has to be developed. A case study on safety helmets is reported. The use of a personal protective device (ppd) is a widely accepted method of safeguarding workers from occupational hazards in industrialized countries (IC) and an important method employed in developing countries (DC). Though protection is assured if the devices are worn constantly, it is unfortunate that due to discomfort and inconvenience, the majority of those exposed to hazards do not wear them. DCs which mainly import ppds from ICs are confronting many ergonomics problems, because the equipment designed for IC conditions is inappropriate for use in DCs, due to significant differences in user body sizes, environments and working methods. A questionnaire survey conducted among ppd manufacturers in 11 ICs revealed that 90% followed standards in manufacturing. Another survey conducted among health and safety authorities who responded on behalf of ppd users in 35 DCs revealed that the most common ergonomic causes of non-use are stresses from hotness, weight, improper fit and obstruction at work. While manufacturers place greater emphasis in the protection performance of the equipment, users in DCs refuse to wear it because the comfort needs are not fulfilled. Developing ergonomics standards for ppds seems to be a feasible way of persuading the manufacturers to provide ergonomic values in ppds. The need for maximum allowable comfort in the design, taking into consideration the user characteristics and protection factor is emphasized. To overcome the inherent discomforts that are extremely difficult to reduce without compromising the protection efficiency of a ppd, the principle of user adaptation seems to be a very important facet which has to be developed. A case study on safety helmets is reported.