Case Studies

excessive noise overexertion injuries caster failure

Excessive Noise

Client:

European Auto Manufacturer

Workplace Issue:

Noise levels above government regulation

Business Impact:	DARCOR Analysis (Site Audit)	DARCOR Recommendation
Long term hearing loss Government fines Union concerns Reduced worker morale	Baseline testing Usage analysis Issue prioritization Floor conditions Weight Frequency of use Target noise levels G-Force testing	Use a wheel with improved shock dampening properties that will reduce G-Forces and noise

Solution:

Darcor Neoprene wheel (D)

Use Darcor Neoprene wheel (W-406-PD)

Improvement To Business (DROI):

Reduced noise levels from 95dB to 80dB
Reduction in G-Force from 40G's to 4G's
Improved work environment
Cost effective solution

Overexertion Injuries

Client:

American Auto Manufacturer

Workplace Issue:

Back injuries occurring as a result of moving heavy loads (600-1400 lbs.)

Business Impact:	DARCOR Analysis (Site Audit)	DARCOR Recommendation
Lost productivity Medical expenses Safety issue Increased maintenance expenses	Floor conditions Weight Frequency of use Cart design Composition of workforce Task specification	Change composition of wheel to reduce rolling resistance Use a wheel with lower compression set and higher resilience Use a precision sealed bearing to reduce maintenance

Solution:

Darcor 400 series caster with Solid Elastomer wheel (SE) and Precision Sealed ball bearings

Darcor 400 series caster with Solid Elastomer wheel (SE) and Precision Sealed ball bearings (31-406-PSE)

Improvement To Business (DROI):

Reduction in workplace injuries
Increase in productivity
Reduction in medical expenses
Lower maintenance expenses

Caster Failure

Client:

Canadian Auto Manufacturer

Workplace Issue:

AGV wheels are wearing out prematurely

Business Impact:	DARCOR Analysis (Site Audit)	DARCOR Recommendation
Increased maintenance expenses Increased wheel costs Decreased productivity/asset utilization	Application Speed of vehicle Floor conditions Loads Wheel diameter/material Bearing construction Shock loads Side thrusts Machine uptime	Use a more resilient wheel that will not generate as much heat Improve bearing construction to one that can withstand side thrusts

Solution:

Darcor 4" Solid Elastomer wheel (SE) with Precision Sealed ball bearings

Use Darcor 4" Solid Elastomer wheel (SE) with Precision Sealed ball bearings (W-74-PSE)

Improvement To Business (DROI):

Reduced the cost of wheel purchase/replacement
Increase in productivity/asset utilization
Reduced noise level in the workplace