Plastic Manufacturer Improves Safety Score by 125% with SM200+ Cart Mover

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

Global Plastics Leader: Innovating with Sustainability and Quality

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

The company specializes in producing a wide range of plastic products and packaging solutions for various industries, serving diverse sectors such as healthcare, food and beverage, consumer goods, and industrial markets.

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

The Challenge of Manually Moving Carts in Manufacturing

The site Health and Safety strategy, led by the EH&S Team, focuses on identifying ergonomic improvements in material handling processes.

One safety improvement identified was the movement of core carts. These carts are used to move products from manufacturing to a staging area, and can weigh up to 5,000lbs. – which were previously moved by hand. Manually moving heavy carts 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 minimize the risk of injuries.

Acknowledging the potential hazards associated with manual handling, the team at the North Carolina plant sought a solution to mechanize the movement of carts, reducing strain on staff and the need for manual labor. In their search for cart moving solutions, they discovered MasterMover Inc., a leading cart tugger manufacturer located in Charlotte, North Carolina.

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

Introducing the SM200+ Cart Mover

The SM200+ is part of MasterMover’s SmartMover range of compact electric tuggers. With a weight capacity of 4,400 lbs., the SM200+ is the ideal manual handling solution, taking the strain of moving heavy carts 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.

Cart Mover in Action:

With a compact design, user-friendly operation, and direct compatibility with the existing core carts, the SM200+ was the perfect solution to make the seamless transition from manual to mechanized.

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

The adoption of MasterMover's SM200+ electric cart tuggers has delivered significant improvements. By eliminating manual handling of heavy carts, the company enhanced ergonomics and workplace safety.

Since implementing the SM200+ walkie tuggers into material movement, the safety score has increased from 4 to 9 – a 125% improvement -at the North Carolina plant, demonstrating the benefits of proactively improving processes and ergonomics.

Benefits of Cart Tuggers in Manufacturing

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

Through the adoption of MasterMover's SM200+ cart movers, 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 electric tuggers can have in industrial settings.