Problem
EHS Manager Ryan Fischer at Iowa Mold Tooling Co. (IMT), Inc. shares how his team put a permanent end to anti-fatigue mat-related trip hazards with custom mats designed to fit.
IMT designs and manufactures mechanics trucks, lube trucks, air compressors, and truck-mounted cranes. To build these products, IMT employees stand long hours and move back and forth across their work cells regularly.
The team at IMT was previously filling workspaces with a random assortment of mats. The piecemeal approach left gaps between mats, caused ergonomic issues, and forced machine operators to constantly watch their feet rather than focus on the work.
"Operators were pushing their mats to the side, a lot of times preferring no mats at all compared to the hodge-podge we had," says Ryan.
Before: IMT was using several styles of mat – each with different thicknesses, surfaces and beveled edges. Out on an island, the mats were also prone to sliding around. Collectively, this created trip hazards and ergonomic inconsistencies for employees.
After: IMT replaced pieced together and "hodge-podge" mats with one-piece custom anti-fatigue mats designed to fit, eliminating trip hazards.
Solution
Summary & Highlights:
- IMT eliminated mat-related trip hazards with custom mats designed to fit
- IMT put an end to curling borders with strategic mat design and materials
- IMT relied on a comprehensive trial process to ensure AcroMat was the right fit
- IMT saved thousands with more durable materials that last years instead of months
- IMT employees are more comfortable and engaged with mats that protect their well-being
Custom Design Eliminates Trip Hazards
In partnership with AcroMat, IMT replaced the random and haphazard mats with custom mats designed and precision-cut to fit each individual workstation – eliminating the need to piece mats together and the mat-related tip hazards caused by gaps and constant on-ff stepping.
The custom mats provide each workstation with consistent cushion, consistent thickness, and a National Floor Safety Institute “High Traction” Certified surface which has proven to reduce wet-slip claims by 50-90%.
The custom-cut shapes, combined with 100% nitrile rubber foam which is engineered to endure even the harshest environments, are now providing operators with an average of 5 years of uninterrupted support compared to the months they were getting from their previous mats.
“AcroMat mats are the brand-new pickup truck I’ve always wanted.”
–Machine Operator, Iowa Molding Tool
Presentation slide created by EHS Manager Ryan Fischer to share benefits of custom mats with IMT corporate leadership. The U-shaped custom mat wraps fully around the workstation, eliminating trip hazards and ergonomic issues from constant on/off stepping.
Permanent End to Curling Edges
Molded from PVC foam, IMT’s previous mats were buckling and breaking down when met with oils, coolants and other products used in the harsh environments. The buckling combined with the "waterfall" designed mats allowed the edges to lift off the ground, creating trip hazards throughout the facility.
In addition to the constant safety issues, the curling borders rendered the mats useless and were taxing the overall safety budget.
Before (left): Waterfall design allowing borders to curl upwards; mat completely flat offering no cushion. Right (after): 100% nitrile with cut-and-bond design guaranteed and warrantied to never sink, flatten or curl.
AcroMat uses an exclusive cut-and-bond design combined with a material that’s impervious to liquids and chemicals. The collective design and materials creates a permanent, ADA-compliant transition to the floor with no threat or risk of curling. In fact, AcroMat guarantees and warranties no curling edges.
“Shoot, I’m 50 years old and have been standing for my job for over 30 years. Why did we have to wait so long to get the good stuff?”
–Machine Operator, Iowa Molding Tool
Extensive Sample Process and Warranty Review
EHS Manager Ryan Fischer was previously with Winnebago Industries, where he played a key role in a project between Winnebago-AcroMat involving the design of 300 custom mats.
With Winnebago, Ryan tested AcroMat mats over several months, making sure they held up in their production environment. After Winnebago saved $150,000 over 5 years because of the higher quality of material, including positive feedback from machine operators, Ryan brough this information to IMT when transitioning roles and shared the AcroMat 2-year full replacement warranty with this team to get buy-in.
IMT had a limited budget for anti-fatigue mats, and couldn’t afford to start over with their matting every few months. They needed mats that would hold up for years at a time without interruption, and guarantees their investment would be protected.
The AcroMat warranty guarantees:
- Your mats will NOT buckle or curl
- Your mats will NOT weaken or come apart at the seams.
- Your mats will NOT curl along the edges or borders.
With AcroMat’s no easy-outs, performance warranty – protecting the company from the most common issues anti-fatigue mat users face – IMT leadership knows with certainty their people and budget are secure.
“These mats are like standing on a cloud. They don’t curl up like our old mats did.”
–Machine Operator, Iowa Molding Tool
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