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CC Apex with Extended Swivel Lead Optimizes Material Handling for Manufacturing Facility

This case study outlines the successful resolution of material handling challenges faced by a manufacturing facility based in Kentucky specializing in automotive components. The facility's Fabrication Team Lead sought assistance in improving the push/pull performance of heavy-duty carts, weighing up to 2,000 pounds. This case study highlights the collaborative efforts and caster solutions that led to remarkable improvements in efficiency and safety.


Operating within the automotive manufacturing sector, this facility produces various components, including radiator supports, body pillars, metal stamping parts, bumper reinforcements, and brake pedals. Its fabrication department faced maneuverability issues related to their heavy-duty carts, particularly when utilized in manual push/pull operations.

Initial Challenges

- Heavy-Duty Carts: This facility utilized heavy-duty carts with a weight capacity of up to 2,000 pounds, which struggled with maneuverability and manual push/pull.

- Safety Concerns: Safety personnel at this facility raised concerns about the challenges associated with push/pull operations, as well as the associated force exerted.

- Push-Pull Efficiency: Initial measurements indicated push-off forces exceeding 55 pounds, which were considered unacceptable. The goal was to reduce this force to around 35-40 pounds or less.

Solution and Implementation

1. Consultation and Analysis: The Fabrication Team Lead initiated a dialogue with David Bausch, a caster solution specialist. They collectively evaluated the existing caster setup and discussed potential solutions.

2. Evaluation of Existing Setup: David Bausch conducted a thorough evaluation of the current caster wheels and cart configuration. Detailed discussions and information exchange helped identify key issues.

3. Recommendation: Based on their analysis, a caster solution was recommended. The proposed setup included maintenance-free 10-inch CC Apex extended lead caster wheels with the option to add brakes for safety.

4. Cart Configuration Adjustment: The Fabrication Team Lead adjusted the cart configuration based on the recommendations, ensuring a more uniform caster setup with matching casters. The goal was to eliminate any conflicts between different caster types.

5. Outcome: Following the caster replacement and cart reconfiguration, the push-pull force was significantly reduced, achieving the desired range of 35-40 pounds, making the maneuverability of the heavy carts remarkably efficient and ergonomic.


1. Enhanced Efficiency: The caster solution resulted in substantial improvements in push-pull operations, reducing the force required and significantly improving cart maneuverability.

2. Safety Improvement: Safety concerns raised by the facility's safety personnel were effectively addressed, contributing to a safer working environment.

3. Operational Satisfaction: The Fabrication Team Lead and his team expressed high satisfaction with the caster solution and the remarkable improvements in cart maneuverability.


The fabrication team lead provided feedback following the implementation of the caster solution. The new caster setup led to remarkable improvements in push-pull force requirements. From previously recording 54-59 pounds of force, they achieved consistent results of around 35 pounds, well within OSHA guidelines. The caster wheels demonstrated exceptional efficiency in starting to move heavy loads, making push-pull operations significantly easier.


The successful resolution of material handling challenges at this manufacturing facility demonstrates the significance of effective collaboration between manufacturers and their suppliers. By addressing specific requirements related to heavy-duty cart maneuverability and push-pull operations, this facility achieved remarkable improvements in efficiency and safety within its facility. This case study highlights the importance of selecting the right caster wheels and maintaining open channels of communication to achieve operational excellence. This facility's experience serves as a practical example of problem-solving and collaboration within the manufacturing sector.