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Case Study: Eliminating Downtime and Boosting Efficiency in Manufacturing with Caster Connection

Boat Manufacturing web

A boat manufacturer was losing 5–6 hours of productivity per week due to failing casters in a fiberglass-heavy production environment. Swivel casters were seizing from debris buildup, causing costly downtime and frequent maintenance. Caster Connection provided a simple yet effective solution—enclosed kingpinless rigs that eliminated debris issues, reduced maintenance by 40%, and kept production moving. Read the full case study to see how the right casters transformed their efficiency.

The Challenge


A manufacturer specializing in tube and joint part carts for a well-known boat manufacturer was facing ongoing mobility issues in its facility. The carts needed to withstand the harsh conditions of a fiberglass-heavy production environment, but its existing casters weren’t holding up. The biggest issue?

  • Swivel casters kept seizing up due to debris buildup in open raceways.
  • Carts were chattering and challenging to turn, slowing down production.
  • Frequent maintenance was required, such as cleaning the raceways weekly to keep things moving.
  • Downtime was piling up, leading to 5 to 6 hours of lost productivity per week.

The manufacturer knew they needed to change. Constant maintenance and downtime cost them money and impacted their ability to meet production demands.

Caster Connection's Solution

When Caster Connection was called in, we immediately saw the problem: debris from the fiberglass production floor collected inside the open raceways, making the casters prone to failure. Our solution? A simple but highly effective upgrade:

Enclosed Kinpinless Rig (Alpha Series)

No more exposed raceways, meaning no more debris issues.

Stronger Load Capacity

The new casters allowed the carts to carry more weight, improving efficiency.

Reduced Downtime

Production could keep running without interruption by eliminating constant maintenance.

CC Alpha Blog Photo web

The upgrade came with a slight price increase—about $10 more per caster—but the benefits outweighed the cost. The manufacturer realized that spending a little more upfront would save them thousands in the long run by cutting labor costs, reducing downtime, and extending the lifespan of their carts.

Results

After switching to Caster Connection’s Alpha rigs, the manufacturer saw immediate and measurable improvements:

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40% Reduction in Long-Term Maintenance Costs

Less time spent on cleaning and repairs.

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5–6 Hours of Weekly Downtime Eliminated

Keeping production moving and reducing labor costs.

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Improved Cart Performance & Efficiency

Smoother rolling, better maneuverability, and increased load capacity.

With the success of the new casters, the manufacturer has now fully transitioned to using Caster Connection’s Alpha rigs on all their carts. The improvements have been so impactful that they no longer worry about seized casters slowing them down.

Conclusion

This case study highlights the power of the right caster solution. By partnering with Caster Connection, the manufacturer eliminated downtime, improved efficiency, and created a more reliable workflow, proving that the right casters make all the difference in keeping production moving.