MTM Employees Who Are Part of Mazda Toyota History in North Alabama

Ergo Cup Competition: Side Pin Extractor

28th Annual Applied Ergonomics Conference

At this year’s 28th Annual Applied Ergonomics Conference, MTM once again showcased its culture of innovation and collaboration by entering the Ergo Cup® Competition. Representing the Tool & Die Maintenance team from our Stamping Shop, our project highlighted a homegrown ergonomic solution: The Side Pin Extractor.

The Ergo Cup® Competition recognizes creative solutions that address workplace ergonomic challenges. Projects are judged on innovation, employee involvement, ergonomic risk reduction, and business impact, and our Side Pin Extractor delivered on all fronts.

The Problem: A High-Risk, Time-Consuming Process

Before our kaizen, removing stuck pins from stamping dies was a physically demanding and inefficient process. Team members used a slide hammer that required high force and awkward posture, often for extended periods. Some extractions took up to 7–8 hours per pin, increasing the risk of injury and production downtime. The constant need to rebuild slide hammer thread adapters only added to the inefficiency.

The Solution: A Tool Designed by the Team, for the Team

Without any prompting from management, team members in Tool & Die identified the hazard and took initiative. Using scrap materials, they designed and fabricated a new Side Pin Extractor that threads into the pin and uses a simple hex nut to apply pulling force. The device can also integrate with a portable hydraulic jack, already in use in the shop, for added efficiency.

Through three major design kaizens—each informed by feedback from team members across shifts—the tool evolved to its current state. The final version is not only effective and safe but also easy to store on preventative maintenance carts, saving additional walk time.

The Impact: Safer, Smarter, Faster

The results speak for themselves:

Ergonomic Risk Reduction

Transitioned from high risk to low risk—eliminating high force, awkward posture, and extended duration.

Productivity Gains

Average of $196 saved per pin.

Injury Cost Avoidance

Estimated annual savings of $25,000.

Cost to Implement

Just $107.20.

ROI

An impressive 41,504.48% with a payback period of less than a day.

A True Team Effort

We’re proud of the Tool & Die team’s commitment to safety and continuous improvement. Special thanks to Jacob P., John K., Tony M., Craig G., Garrett C., Jason D., Ken B., and Daniel B., as well as every Tool & Die team member who contributed to the design iterations. At MTM, even our smallest teams drive significant change. The Side Pin Extractor is more than just a tool—it’s a testament to the power of collaboration and the ingenuity of our people.