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The Situation: Cart operators at a Big Three Powertrain Facility experienced push/pull injuries when moving 1000 lb. carts. These carts used industry-standard balloon tread wheels, which didn’t take long to show signs of wear.

The situation resulted in operators exerting greater muscle strength to move the heavy carts, significantly increasing overexertion injuries and workers’ compensation costs. Three injuries in the last year alone cost the facility more than $60,000. So Caster Concepts decided to introduce Twergo® Casters.

By allowing the body to move naturally, we reduce the risk of injury. When a process requires a person to push more, pull harder, overextend their body, or make other movements beyond the normal range of motion, unfavourable conditions arise. The person must exert greater muscle strength, significantly increasing the risk of an overexertion injury.

The Solution: The plant soon got in contact with Caster Concepts. After assessing the situation, the Caster Concept’s engineering team determined that the Twergo® Casters wheel would be the best solution. Twergo wheels are designed to rotate independently. This design reduces friction and the force needed to push a cart.

The Savings: The ergonomic benefits realized included reducing push force from 30 pounds to 17 pounds, a reduction of almost 50%. This also eliminated expensive workers comp injuries, as the risk of injury shifted to below 1% from the previous 20%. This helped the facility get a return on investment in only 3 months.

For more information, contact a Caster Concepts sales professional at 517-680-7950.