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Case Study: TWERGO® Reduces Initial Push Force for US Automaker

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The largest automaker in the United States was having issues with initial push force on various material handling carts in its facility, each with about a 10,000 lbs. load. On these carts, initial push force averaged approximately 70 lbs. of pressure exerted per cart, far greater than OSHA recommendations for push pull force. Perhaps worse, the carts required two operators to start rolling, which reduces productivity and increases cost.

Lastly, there was significant amounts of debris on the floor which builds up on the caster wheels and further exacerbates the initial push force issue. Carts were being pulled out of use so that the debris could be cleaned off the wheels. This created another drain on productivity.

The engineers at the facility contacted Caster Concepts and challenged them to reduce the push force on the carts while also eliminating the accumulation of debris on the wheels.

The Caster Concepts engineering team suggested they use 10” and 12” diameter triple-wheel TWERGO® casters with ErgoTread material in ErgoMaxx™ rigs.

The result was dramatic. Initial push force on the carts was reduced to about 40 lbs. of pressure and the ErgoTread material repelled the floor debris, significantly reducing build up. The TWERGO® products increased productivity by eliminating the need for two operators to start movement. It has been reported that floor operators request the carts with the “green wheels” and the maintenance team can’t switch the wheels on the carts over fast enough.

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