One of the world’s largest automotive manufacturers approached Tractive Power with a specific challenge. The goal was to reduce downtime during moulding machine changeovers while ensuring that operator safety and production quality were not compromised.
This partnership became a perfect example of how improving automotive processes with Tractive Power’s innovative equipment leads to measurable gains in productivity, safety, and lean manufacturing efficiency.
The Challenge: Reducing Die Changeover Times
The client needed to streamline the process of switching between left-hand drive and right-hand drive dashboard production. At the time, this changeover took over two hours per shift. The method required multiple operators to manually move heavy moulding dies in and out of position, posing a significant risk of injury and disrupting production efficiency.
As part of their broader Kaizen implementation, the company sought a safer, faster, and standardised solution to this operational bottleneck.
Kaizen in Action: A New Approach to Die Handling
In alignment with their Kaizen philosophy, the manufacturer re-evaluated the die-handling process. The goal was to improve the overall workflow by placing the heavy dies on custom-engineered trolleys, which would allow the dies to be moved more efficiently.
However, manual handling still required multiple staff, raised safety concerns, and created inconsistency in execution.
This is where Tractive Power’s TP250 Compact Tractive Pusher came in as the ideal solution.
The Solution: TP250 Tractive Unit
Tractive Power supplied the company with the TP250 Compact Tractive Pusher, a battery-powered, pedestrian-operated tug capable of moving trolleys weighing up to 2,000kg. With this unit, a single operator could safely and effortlessly move the moulding dies into position—reducing the changeover time from two hours to just 15 minutes.
Key Benefits Delivered:
- 75% reduction in die changeover time
- Single-operator process, improving labour efficiency
- Improved health and safety, removing the need for manual pushing
- Easy integration with custom trolleys and moulding equipment
- Consistent, repeatable results across global factory sites
A Scalable Solution Across Global Operations
Following the successful implementation of the TP250 unit at their UK site, the manufacturer quickly adopted this system across multiple international facilities. It has now become a standardised best practice for die changeovers within their global operations.
By working with Tractive Power, the company achieved a sustainable process improvement. Aligning with their lean manufacturing goals, while also supporting employee wellbeing and operational consistency.
Why Tractive Power for Automotive Manufacturing?
This case study demonstrates how Tractive Power’s electric tugs and pushers can play a key role in improving automotive processes, especially in areas like tool changeovers, heavy parts movement, and materials handling.
Our equipment is:
- Compact and easy to manoeuvre, even in tight factory spaces
- Battery-powered and pedestrian-operated, requiring no forklift license
- Customisable to suit unique operational needs
- Designed for safety, with proportional speed control and robust handling
Ready to Improve Your Automotive Process?
If you’re looking to improve changeover times, reduce manual handling, or streamline your automotive production process, Tractive Power can help.
Explore our TP250 Tractive Pusher or contact us to speak with one of our team members about your requirements.
Get in touch today and discover how our tugs can help you improve safety, efficiency, and productivity on your shop floor.