As reported in the article “Tire Manufacturer Sees 71% Push Force Reduction on Carts with Twergo®,” being one of the world’s largest tire manufacturers comes with a hectic production schedule. Like many manufacturers, material handling carts play a crucial role in keeping the assembly lines moving.
The tire company faced a significant challenge with four cart designs that were not only heavy but incredibly hard to push. This challenge resulted in overexertion injuries, including multiple strains to elbows, shoulders, and the upper back, leading to a long list of complaints.
Across various locations, up to 118 operators handled these heavy carts daily, exerting push forces of up to 120 lbs. when full. It was a substantial ergonomic challenge, and this issue wasn’t isolated.
The company’s ergonomist, Dave C, collaborated to address these cart-related issues. After a thorough review of the problematic cart designs, precise measurements were taken to determine the appropriate caster size. Three sets of Twergo® casters were provided for a trial run.
The results were remarkable. As Dave puts it, “Boy, was Paul right. After trialing the casters on the 4 cart designs, we’ve seen an immediate 71% reduction in push force!” Such a significant reduction was both unexpected and greatly appreciated, as the ergonomist had never achieved such results from a caster change or upgrade before. Notably, this push-force reduction delighted the cart operators.
By transitioning to Caster Concepts’ Twergo casters, more than 60 high-risk tasks were eliminated, positively impacting over 500 total cart operators.
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