Caster Autopsies: Why Did they Die?

Caster Autopsies: Why Did they Die?
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Presented by:
Lui Dilauro
Dave Lippert
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Why Did They Die?
5 Autopsies
• Serious overload – large caster
• Corrosion – pallet trucks
• Side load casualty – cart in distribution
center
• Debris Pickup – wheel material
• Durability – wheel material
Large Caster Overload
Large Caster Overload
Large Caster Overload
Large Caster Overload
Large Caster Overload
• Lessons Learned
– Consider more than total load, caster
quantity
– Load distribution, uneven surface
– Likelihood of overload
– Alternatives: More casters, oscillating
axles, spring loaded casters
Corrosion – Pallet Trucks
Corrosion – Pallet Trucks
Corrosion – Pallet Trucks
Corrosion – Pallet Trucks
Corrosion – Pallet Trucks
• Lessons Learned
– Environment matters.
– Food service applications,
slaughterhouses, have environmental
challenges to steel parts.
– Downtime is expensive
– Appropriate countermeasures can help to
avoid the environmental problems.
Side Load Casualty
• Process changed, but not casters
Side Load Casualty
Side Load Casualty
Side Load Casualty
• Lessons Learned
– Casters that work on carts in one
application don’t automatically work in a
different one.
– Side load forces applied by forklifts can be
significant.
– Not all casters are designed to handle
significant side load forces.
– Unnecessary costs occurred due to wrong
“assumption.”
Debris Pickup – Wheel Material
• Background – White Goods Manufacturer
– Cart capacity: 1500 lbs.
– Towing speed: 7 MPH (max)
– Caster configuration: 2 swivel, 2 rigid
– Wheels: 6” diameter
– Conditions: metal shavings, floor pitting
– Goal: Good ergonomic performance, no
debris collection on wheels.
Debris Pickup – Wheel Material
Debris Pickup – Wheel Material
• Lessons Learned
– Debris “resistant” vs. debris “free”
– Wrong caster = downtime, production
costs
– Understand needs and environment
– Price isn’t everything!
– Right casters are assets
Durability – Wheel Material
• Background – manufacturing facility
– Cart capacity: 1800 lbs.
– Towing speed: 7 MPH (max)
– Caster configuration: 2 swivel, 2 rigid
– Wheels: 6” diameter
– Conditions: debris, solvents, oil, plastic wraps
– Goal: Good ergonomics, also durability
Durability – Wheel Material
Durability – Wheel Material
• Lessons Learned
– Actual capacities matter
– “G” forces on casters
– Shock loading – where and when
– Importance of wheel tread resiliency
– Communicate performance expectations
Case Summary
•
•
•
•
•
Wheels and casters matter
Application details are important
Environmental details are important
Avoid surprises
Ask – don’t assume
Questions???
ICWM Members
For More Information:
Lui Dilauro email: [email protected]
Website: www.darcor.com
Dave Lippert email: [email protected]
Website: www.hamiltoncaster.com
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