Leyland Trucks takes on electric tugs for safer handling

The use of two SmartMover SM100 models allows heavy pre-assembled modules to be moved by a single operator, freeing up valuable manpower.

The need for a safe, robust materials handling solution came about after Leyland Trucks implemented several new assembly processes in order to build its new Euro 6 vehicles. This includes a state-of-the-art alignment system that utilises a pre alignment assembly system before transferring the vehicle to the main build conveyor.

Leyland Trucks facilities and maintenance manager Marc Oakley was conscious of the efficiency and health & safety risks involved in moving the pre alignment assembly system – which weighs around 1,000 kg – by hand.

“Not only did it take two or three guys to push the units across the floor, we were worried about the process causing an accident or long-term repetitive strain injury,” he explains.

Leyland Trucks investigated options on the market and discovered MasterMover. The benefits of MasterMover technology were immediately obvious and Leyland Trucks contacted the company to set up a trial.

Several tugs were tested, with MasterMover and Leyland Trucks deciding that the SmartMover – the company’s biggest-selling model – was the most appropriate solution.

The SmartMover is a compact, versatile unit capable of moving up to 1,200kg on castors. When it is coupled to the load, it utilises tractive force to take the weight of the load away from the operator for a comfortable, controlled journey across the factory.

Since the SmartMovers arrived at the factory in April 2013, Leyland Trucks has implemented a safer and more efficient routine for moving the pre alignment assembly system.

“Now it only takes one operator, thus freeing up valuable manpower resource to be utilised elsewhere,” confirms Marc Oakley. 

“In addition, with the SmartMover bearing the brunt of the load, our operator can move the unit in a manner that significant reduces risks to health and safety.”

Leyland Trucks uses the SmartMovers every day and has been impressed by their reliability.

“As manufacturers ourselves, we appreciate the value of well-engineered equipment and MasterMover offers a superbly designed and highly functional solution to the issue of moving heavy loads within the factory,” concludes Marc Oakley.