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CC Nexus Improves Ergonomic Performance and Operational Efficiency at Midwest Automotive Plant

This case study examines how an American automotive company with an engine plant in the Midwest successfully addressed ergonomic challenges in their assembly process through collaboration with Caster Connection.

The study focuses on the transformation of a heavy turntable cart used in the engine assembly area of the plant. The case highlights the efficacy of CC Nexus. It also showcases how the solution specialists at Caster Connection collaborate with the plant supervisors, ergonomists, and engineering teams to develop a specialized solution that improves ergonomic performance, safety, and operational efficiency.

Background:

This engine plant faced a challenge with a turntable cart used in the V6 engine assembly process that weighed 2,760 pounds. The ergonomic push/pull force required to move the cart was well above the acceptable limit of 45 pounds. This high force created safety concerns and required multiple crew members to operate safely during manual applications to reduce physical strain on the workers. The solution provided by Eric Hassen of Caster Connection eliminated this ergonomic risk factor. It also allowed the turntable cart to be operated by a single crew member while still adhering to rigorous ergonomic and safety standards.

Key Players:

- A Manufacturing Engineering Team Manager at the engine plant.

- A Union Ergonomics Representative at the engine plant.

- Eric: Director of Sales and Solution Specialist from Caster Connection.

Challenges:

- The turntable cart was heavy and required excessive force for manual push/pull, leading to ergonomic safety and staffing concerns.

- The weight distribution of the cart, which was significantly heavier in the back, required a customized solution to comply with ergonomic restrictions.

- The cart needed to meet strict height and dimension requirements due to its usage with a lift table.

Collaborative Solution:

1. The union ergonomics representative contacted Caster Connection, raising concerns about the high push/pull force required to move the cart.

2. Eric, Caster Connection's lead solution specialist, visited the engine plant to assess the situation and understand the cart's design and usage.

3. After testing various caster options, the Caster Connection solution proposed by Eric Hassen utilized a combination of modular multi-wheel 8" CC Nexus casters featuring an extended swivel lead and rigid CC Stout casters for the cart's front and rear, respectively.

4. This combination of casters effectively distributed the weight and minimized compression, making the cart easier to move while staying within the strict height and dimension requirements.

Implementation:

1. Caster Connection sent samples of the proposed caster combination to the automotive engine plant.

2. Testing took place in January of 2023, confirming that the proposed caster combination reduced the ergonomic push/pull force to an acceptable level.

3. The solution was implemented in the V6 engine assembly area, improving ergonomics and reducing physical strain on workers.

Results:

- The ergonomic push/pull force for the turntable cart was successfully reduced to under 45 pounds.

- Using the combination of CC Nexus swivel casters on the front of the cart and rigid CC Stout casters on the heavier backend of the cart dramatically improved weight distribution and minimized compression, making the cart easier to move.

- The implementation of the caster solution enhanced worker safety, improved ergonomic performance, and alleviated potential staffing issues, contributing to a more efficient assembly process.

Future Implications:

- The successful application of the caster solution at automotive engine plant could serve as a model for addressing similar ergonomic challenges across other automotive manufacturing facilities.

- The collaboration between this American automotive plant and Caster Connection showcases the importance of seeking specialized solutions to improve operational efficiency and employee well-being.

Conclusion

The collaboration between this engine plant and Caster Connection demonstrates how a targeted solution can address ergonomic challenges and improve operational efficiency. Combining expertise from both sides reduced the heavy turntable cart's ergonomic push/pull force to an acceptable level, resulting in safer and more efficient assembly processes. This case study highlights the importance of collaboration and specialized solutions in tackling complex manufacturing challenges.

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