SM200+ Helps Plastic Manufacturer Improve Safety Score by 125%

A Fortune 500 manufacturer of plastic packaging products has implemented MasterMover’s electric tug solutions to drive safer operations and eliminate manual handling in their material handling processes at their facility in North Carolina, USA - improving the site safety score by 125%.

Global Plastics Manufacturer: Innovating with Sustainability and Quality

Headquartered in the Midwest of the United States, this leading plastic manufacturer operates multiple facilities across North America and has over 250 facilities globally.

The company specialises in producing a wide range of plastic products and packaging solutions for various industries, serving sectors including healthcare, food and beverage, consumer goods, and industrial manufacturing sectors.

With a focus on innovation and sustainability, this organisation continues to expand its operations and maintain its position as a leading provider of high-quality plastic products in the United States and globally.

The Challenge of Manually Moving Heavy Loads in Manufacturing

The site Health and Safety strategy, led by the HSE Team, focuses on identifying safety improvements in material handling processes.

One safety improvement identified was the movement of material trolleys. These trolleys are used to move products from manufacturing to a staging area, and can weigh up to 2,000kg. – which were previously moved by hand. Manually moving heavy trolleys presents a risk of injuries, particularly where movements are repetitive or over long distances.

The previous handling process was rated with a safety score of 4, prompting the team to explore ways to improve operational safety and minimise the risk of injuries and fatigue.

Acknowledging the potential hazards associated with manual handling, the team at the North Carolina plant sought a mechanical aid to support the movement of trolleys, reducing strain on staff and the need for manual handling. In their search for safer load moving solutions, they discovered MasterMover Inc., a leading electric tug manufacturer located in Charlotte, North Carolina.

Upon consultation with Carolina Handling, a MasterMover sales partner, the manufacturer selected the SmartMover SM200+.

Introducing the SM200+ Cart Mover

The SM200+ is part of MasterMover’s SmartMover range of compact electric tug solutions. With a weight capacity of up to 2,000kg, the SM200+ is the ideal manual handling aid, taking the strain of moving heavy trolleys  and improving operator safety.

A demonstration of the SM200+ was carried out at the North Carolina site and quickly proved that the SM200+ was the right solution. Following the successful demonstration, an order was placed for two machines to be used across processes.

SM200+ Electric Tug in Action:

With a compact design, user-friendly operation, and direct compatibility with the existing trolleys on-site, the SM200+ was the perfect solution to make the seamless transition from manual to mechanised material movements.

Improved Material Handling Safety Score from 4 to 9 with SM200+ 

The adoption of MasterMover's SM200+ pedestrian tugs has delivered significant improvements. By eliminating manual handling of heavy trolleys, the company enhanced ergonomics and workplace safety.

Since implementing the SM200+ tugs into material movement, the safety score has increased from 4 to 9 – a 125% improvement, demonstrating the benefits of proactively improving processes and ergonomics.

Benefits of Manual Handling Tugs in Manufacturing

The success of the SM200+ at this customer's North Carolina facility has sparked interest in its potential implementation at other locations across the United States and further afield, indicating promising future prospects for enhanced safety and efficiency throughout the company's operations.

Through the adoption of MasterMover's SM200+  tugs, the North Carolina plant successfully addressed the challenges of manual handling, significantly improving safety and productivity in their material handling processes.

This case study underscores the importance of proactive measures in workplace safety and highlights the transformative impact pedestrian tug solutions can have in industrial settings.