A manufacturing facility in Kentucky was struggling with material handling challenges while transporting automotive components on their heavy-duty carts, which weigh over 2,000 pounds. By replacing their existing casters with CC Apex extended swivel lead casters, Caster Connection was able to improve push/pull performance, worker safety, and efficiency for the manufacturing facility.
Operating within the automotive manufacturing sector, this facility produces a range of components, including radiator supports, body pillars, metal stamping parts, bumper reinforcements, and brake pedals. However, the fabrication department encountered maneuverability issues with their heavy-duty carts, particularly during manual push/pull operations.
Automotive Component Manufacturing
CC Apex Extended Swivel Lead
Ergonomics, push/pull efficiency, and safety
The manufacturing facility faced several significant challenges that hindered its operational efficiency. With heavy-duty carts weighing over 2,000 pounds, the team encountered difficulties in maneuverability and ergonomics, especially during manual push/pull operations. These challenges not only affected productivity but also raised safety concerns among the team. The following points detail the specific obstacles the facility needed to overcome to enhance their material handling processes.
The facility utilized heavy-duty carts with a weight capacity upwards of 2,000 pounds. These carts struggled with maneuverability during manual push/pull operations.
Safety personnel raised concerns regarding the challenges associated with push/pull operations, particularly the excessive force exerted by the shoulders and back during these activities.
Initial measurements indicated push-off forces exceeding 55 pounds, which were deemed unacceptable. The goal was to reduce this force to approximately 35-40 pounds or less.
Recognizing the need for improvement, the Fabrication Team Lead reached out to Caster Connection, where they were matched with a caster solutions representative. Together, they initiated a collaborative dialogue to assess the existing caster setup. This partnership laid the groundwork for a comprehensive solution tailored to the facility's unique challenges.
The caster solutions representative conducted a meticulous evaluation of the current caster wheels and cart configuration. Through in-depth discussions and caster audits, they uncovered the root causes of the maneuverability issues, setting the stage for effective solutions.
Drawing from their analysis, Caster Connection proposed a game-changing caster solution. The recommendation included maintenance-free 10-inch CC Apex extended lead casters, designed to address the client's ergonomics and maneuverability pain points. To further enhance safety, they included an option to add brakes, ensuring that the carts would operate smoothly and securely.
With the proposed solution in hand, the Fabrication Team Lead took action, adjusting the cart configuration to align with the recommendations. By implementing a uniform caster setup with matching casters, they eliminated conflicts between different types, paving the way for a more efficient operation.
The transformation was remarkable. Following the caster replacement and cart reconfiguration, the push/pull force was drastically reduced, achieving the desired range of 35-40 pounds. This significant improvement enhanced the maneuverability of the heavy carts, making them not only easier to handle but also more ergonomic for operators.
The implementation of the extended lead CC Apex casters yielded impressive results that transformed the facility's material handling capabilities. The changes not only addressed the initial challenges but also delivered substantial benefits in efficiency, safety, and overall effectiveness.
The new caster solution dramatically improved the maneuverability of the heavy-duty carts, facilitating more seamless performance and reducing operator fatigue.
With lower push/pull forces, the risk of injuries associated with manual handling was minimized, contributing to a safer work environment.
The enhanced maneuverability led to faster workflow processes, enabling the facility to increase overall productivity in their operations.
The successful implementation of extended swivel lead CC Apex casters has demonstrated the profound impact that the right caster solution can have on a manufacturing facility's operations. By addressing the specific challenges related to maneuverability and push/pull efficiency, these casters not only enhanced the safety and ergonomics of heavy-duty cart handling but also significantly improved overall productivity.
The durability and resilience of CC Apex casters make them an excellent choice for demanding environments, such as automotive manufacturing. This case study exemplifies how investing in high-quality caster solutions can lead to tangible improvements in material handling processes, ultimately contributing to a more efficient and safer workplace.
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