Ergo Cup Competition: LLC Cap Remover
29th Annual Applied Ergonomics Conference
At the 29th Annual Applied Ergonomics Conference, MTM once again brought forward a practical, people-focused solution to the Ergo Cup® Competition: the LLC Cap Remover. The Ergo Cup® is a conference where companies come together to present innovative solutions that address ergonomic challenges in the workplace and improve processes and systems.
On the Discovery Line, team members in Assembly-specifically in the final liquid fill area-were required to repeatedly grip and remove an LLC cap, resulting in upper-extremity strain over time. The opportunity to improve the removal process became clear, allowing team members to perform the task more safely and efficiently.
The project also reflects how creativity and technology are changing the way workplace challenges are solved. With the accessibility of tools like 3D printing, teams can now rapidly create custom solutions that would have been significantly more difficult, costly, and time-consuming to develop just a few years ago.
The Problem: Repetition That Adds Up
Removing LLC caps required repeated manual effort throughout the shift, often involving awkward wrist positioning, grip force, and repetitive upper-body motion. Team members described strain not only in the hands and wrists but also in the shoulders and upper arms due to the force and repetition required to consistently complete the task throughout production. Although the task itself may have appeared small, the frequency of the motion made it a meaningful ergonomic concern. Over time, the repetitive strain caused discomfort and increased the risk of injury for team members who performed the process daily.
Beyond the physical strain on team members, repetitive ergonomic issues can also have a significant operational impact. When injuries occur, costs extend far beyond immediate medical treatment and can include administrative expenses, incident investigations, recovery time, time away from the line, retraining, and coverage for affected team member roles. Using estimated injury-related costs of $25,000 per incident, even a small number of ergonomic injuries can have a substantial long-term impact on both team members and operations.
Recognizing both the immediate and long-term risks, the team knew a better solution was needed, one that would not only improve the process but also better support the people performing the work every day.
The Solution: Iteration, Innovation, and Ownership
Rather than settling for a temporary fix, the team leaned into Kaizen, continuously refining their approach until they found a solution that not only worked but also truly supported team members.
Using 3D printing, they were able to quickly prototype and adjust designs, creating a tool tailored specifically to the task. Each iteration brought improvements, guided by real-world use and team feedback.
At MTM, innovation drives everything we do. By collaborating across departments and embracing continuous improvement, we enhance safety, quality, and efficiency throughout our operations.
The Impact: Meaningful Improvement in Everyday Work
Ergonomic Risk Reduction
Reduced grip force by up to 75%, improved wrist posture by eliminating twisting motions, and allowed team members to maintain a more neutral wrist position by pushing straight forward during the process. The addition of a handle to the LLC Cap Remover also reduced the reach distance for team members, further improving ergonomics and reducing upper-body strain.
Injury Cost Avoidance
Cost to Implement
ROI
Team Member Pride: Recognizing the Value of Small Wins
“I had so much pride in seeing our team present the project and recognize the value in the small but significant change that they were a part of,” shared Ashley, an MTM team member involved in the project. “It was inspiring and reassuring to see other companies that also value engagement, ergonomic improvement, and the many benefits that come with those.”
The project reflects MTM’s continued commitment to teamwork, innovation, and continuous improvement. By staying focused on supporting team members and embracing creative problem-solving, even small changes can create a lasting impact.