Reducing Ergonomic Push/Pull Issues for an Industry-Leading Electric Vehicle Manufacturer
In an effort to improve operational efficiency and reduce ergonomic strain for their associates, an industry-leading electric vehicle manufacturer sought assistance in addressing severe Push Pull issues with their Body Frame cart, leading them to partner with Caster Connection for a tailored mobility solution.
Background
An industry leader in electric vehicle manufacturing was experiencing significant ergonomic challenges with their Body Frame cart. The existing setup required an excessive amount of force to move the cart, often necessitating the effort of three associates. This situation was not only inefficient but also posed a risk to the associates’ safety and productivity.
Issue
The Body Frame cart exhibited extreme push/pull issues, requiring around 160 pounds of force to initiate movement when loaded. The goal was to reduce the ergonomic strain associated with this task while maintaining the same dimensions of the casters, if possible.
Original Setup
The cart was equipped with 8x2 swivel casters from a competitor. Initial testing revealed the following Push Pull forces:
• Unloaded Cart:
• Trial 1: 42 lbs
• Trial 2: 48 lbs
• Trial 3: 61 lbs
• Trial 4: 58 lbs
• Loaded Cart:
• For all four push trials, the gauge consistently read around 110 lbs, but the cart did not move. The estimated push force required to get the cart moving was approximately 160 lbs.
Proposed Solution
Caster Connection was brought in by a representative from the electric vehicle manufacturer to address the issue. After discussions with the team, it was recommended to test the 8x2 CC Nexus Maintenance Free swivel casters with extended lead and swivel locks. These casters were selected due to their precise maintenance-free swivel raceway, extended swivel lead, and split wheel design, offering the best option for polyurethane wheels at the current weight.
Testing & Results
After installation, the cart was immediately found to be much easier to push by multiple team members. Formal push-pull testing showed significant improvements:
• Unloaded Cart:
• Trial 1: 35 lbs.
• Trial 2: 46 lbs.
• Trial 3: 42 lbs.
• Trial 4: 44 lbs.
• Loaded Cart:
• Trial 1: 62 lbs.
• Trial 2: 65 lbs.
• Trial 3: 71 lbs.
• Trial 4: 67 lbs.
This resulted in an estimated 58-60% reduction in push-pull forces compared to the original casters.
Feedback
The new casters received overwhelmingly positive feedback from the team. One representative expressed their satisfaction, stating, “You have changed my life” with the new casters.
Conclusion & Recommendations
The installation of the CC Nexus casters provided a substantial ergonomic improvement. While further reductions in push-pull forces could be achieved with additional modifications, such as changing the top plate and adjusting the cart’s height, the current reduction may already meet the manufacturer’s needs.
Caster Connection remains available for further consultation and testing to ensure the optimal solution for this electric vehicle manufacturer’s operational requirements.