CAS Ergo

CAS Ergo

Collaboration with other companies for our CAS Ergo range at CAS Assembly Tooling and Services is really important to us. Recently HUNIC did a question and answer session about the benefits of the Exoskeleton which we wanted to share on our news page as the UK supplier.

From Skepticism to Success: Overcoming Challenges with Passive Exoskeletons

July 9, 2024

Jan Rupprich, Key Account Manager at HUNIC, delves into the transformative impact of passive exoskeletons on workplace well-being. With his vast experience, Jan shares insights on overcoming common fears and obstacles, and reveals how these innovative devices can boost productivity and reduce injuries.

Today, we’re exploring a cutting-edge solution to workplace well-being: passive exoskeletons. Let’s start with a quick breakdown.

Can you explain what they are and how they benefit businesses?


Absolutely. Imagine wearable tech that supports your workers, just like a trusted teammate. Passive exoskeletons are exactly that. They’re lightweight, user-friendly devices that reduce strain and fatigue, especially during repetitive or physically demanding tasks. The result? A happier, healthier workforce that’s more productive and less prone to injuries.


Sounds impressive! But change can be tricky. What are some common hurdles companies face when implementing this technology?


Great question. Sometimes, employees might be hesitant about using something new. It’s natural! We address this by providing clear explanations and hands-on demonstrations. Workers get to experience the benefits firsthand and see how the exoskeletons seamlessly integrate into their workflow.


Speaking of misconceptions, are there any myths you encounter frequently?


Definitely. Some might think exoskeletons are bulky or uncomfortable. In reality, they’re ergonomically designed for ease of use. Another misconception is that they slow workers down. Actually, by reducing fatigue, they can even enhance performance!


Interesting. How important is management support in overcoming these initial obstacles?


Critically important! When leaders actively champion the implementation, it sends a strong message of support to the team. They can also facilitate open communication and ensure a seamless transition.


And beyond the initial setup, what’s the secret to long-term success?


Ongoing support is key. We offer regular check-ins, additional training sessions, and maintenance services. It’s all about ensuring the exoskeletons continue to meet the evolving needs of the workforce.


Can you share a real-world example where HUNIC SoftExos made a positive impact?


Absolutely! We had a client in manufacturing where there was initial resistance. However, after a comprehensive training program and pilot phase, the feedback was overwhelmingly positive. Workers reported feeling less fatigued, and the company saw a significant decrease in injuries. This success story is now a blueprint for us to help other companies achieve similar results.


Excellent. Any final advice for companies considering passive exoskeletons?


Make it a collaborative effort! Involve your workforce from the beginning, provide comprehensive training, and be open to feedback. By prioritising worker well-being and fostering transparency, you can create a safer, more productive workplace for everyone.


Thank you for sharing your expertise! It’s clear that HUNIC SoftExos, with the right approach, can empower companies to create a win-win situation for both employees and the business. Overcoming initial resistance through training and management support is key. Long-term success depends on ongoing support. Success stories like HUNIC SoftExos show the benefits. Prioritising employee well-being and collaboration leads to a safer, more productive work environment.

At CAS Ergo we offer a demonstration, booked in advance. Contact us.

Hunic Exoskelton suits at CAS Assembly and Tooling in Birmingham

We would love to share with you how these benefit employees and help them become more productive. Contact our Sales Director Neil on 0121 327 1700 or on his mobile, 07717 202225. Alternatively, send an email to NEVANS@CAS-LTD.UK.COM to book in your trial.

YMCA Sleepout – 2023

YMCA Sleepout – 2023

YMCA – Sleepout 2023

The YMCA – Sleepout 2023 is an event organised each year to raise money for the homeless in and around the Burton on Trent area. Our Financial Director Brian, and his wife Sarah are participating in 8 days time, in the sleepout,  joining over 100 other amazing people. They are all giving up their warm, comfy beds for one night so that others don’t have to.

Sarah originates from Burton on Trent and the YMCA charity has always been something close to her heart. After learning about what the fundraisers do and the volunteers recently it’s opened her eyes as to what homeless people go through, often through no fault of their own.

The YMCA know from experience that working with homelessness, prevention, and outreach that there are many fears and anxieties felt by people experiencing this dreadful situation.

  • No one wakes up and decides to be homeless out of choice and everyone has a different story.

What are they?

  • Anxious about safety and fear of abuse or attack.
  • Isolation, loneliness and cut off from society
  • Lack of stability and a safe place to stay
  • No access to basic washing facilities or even health services
  • Finding somewhere to sleep that offers cover from the weather elements and then it is poor quality sleep.

Homelessness and the fear of it can be debilitating mentally and physically.

YMCA - Sleepout 2023, Brian and Sarah at CAS Assembly Tooling and Services do their 'bit' for charity!

This year, CAS have sponsored a cardboard box for the YMCA – Sleepout 2023. We are looking for sponsorship to help with our chosen charity this year.😉

If anyone has a few pounds to help support this amazing charity and the work the volunteers do, we’d appreciate it. Here’s the link.

Good luck Brian and Sarah sleeping outside, in a cardboard box. This will be their shelter, in a tunnel at Burton Albion Football Club.📦😬

To find out more about the YMCA, check out this link.

Prestigious Nomination from XPO Logistics for CAS!

Prestigious Nomination from XPO Logistics for CAS!

Prestigious nomination for CAS! – CAS Assembly Tooling and Services receive a nomination to provide Hunic Suits 

XPO Logistics roll out the Hunic Exoskeleton to all parts of the UK and Ireland after a highly successful safety and wellbeing trial

London, UK – 14 September 2023

In a significant milestone for the tooling and manufacturing industry, CAS Assembly and Tooling are proud to announce its nomination as a Hunic Exoskeleton provider by XPO Logistics Europe.

This coveted recognition underscores CAS Assembly and Tooling’s unwavering commitment to excellence. Also innovation in the realm of assembly solutions and tooling health and safety.

The nomination as a Hunic provider positions CAS Assembly and Tooling among the elite in the industry. This solidifies the reputation as pioneers and leaders in health and safety excellence. With a proven track record of delivering cutting-edge solutions and a commitment to driving forward the future of assembly, tooling and services, the selection as a Hunic Suit provider under our banner of ‘CAS Ergo’ is a testament to our dedication and expertise. Health and Safety at work is so important for employee’s ability to do there jobs successfully and correctly.

With our commitment to providing state-of-the-art solutions that exceed customer expectations, CAS have not only excelled in the industry but also set new benchmarks for others to follow.

XPO, a leading provider of innovative and sustainable transport and logistics solutions in Europe, has successfully completed a pilot trial of Hunic safety equipment  at specific sites within the business and will deploy the exoskeletons across the whole of the UK and Ireland.

Using the Hunic Exoskeleton assists XPO colleagues with heavy lifting duties, ensuring their posture is correct to reduce the chance of injury. It has also significantly reduced the fatigue felt by those working in the five depots where the suits were tested, boosting productivity.

The main benefits are:

 The back support ensures a straight back and an upright position.
 Elastomers support the leg muscles when lifting from a crouch.
 The additional support the wearer gets in overbending of the spine.
 Body position remains upright when standing and walking.
 Elastomers provide up to 21% assistance in standing from crouched.

Ian Fox, head of health and safety – UK and Ireland, XPO Logistics, said: “The feedback from the users of the exoskeletons during the pilot was hugely positive. The wearers reported significantly less fatigue and effort required in the routine handling activities, which has supported the decision to expand the use and invest in the equipment for the benefit of our colleagues.”

“Additionally, we found that the exoskeleton assists in forming good postural habits that will continue into life in general when not wearing the equipment.”

We hear the phrase ‘muscle memory’ a lot these days. So, safe practices are also being taken home as well.

The Hunic Exoskeleton is designed to prevent the wearer from lifting with an incorrect posture. It will only allow the body to move in connection with safe manual handling techniques. It will not, for example, allow the back to have incorrect posture movements. The suit helps the wearer undertake repetitive lifting safely whilst improving turnaround time.

As a result of lower fatigue when wearing the suits, XPO has seen a 15-20% reduction in unloading time on Samsung containers. This means increased productivity for those wearing them.

XPO expects to deploy the exoskeleton across the UK and Ireland before the end of the year after the successful pilot at specific business sites.

A Prestigious nomination for CAS!👌

 Prestigious Nomination from XPO Logistics for CAS! CAS Assembly Tooling and Services , Hunic Exoskeleton

The Hunic (Soft Exo) Suit in action

For enquiries, and a demo, please contact CAS Assembly Tooling and Services Sales Director, Neil on 07717 202225.


🌟Testimonial Tuesday!🌟

🌟Testimonial Tuesday!🌟

🌟Testimonial Tuesday!🌟

👉Great to have received these comments recently and it’s not every Tuesday it’s 🌟Testimonial Tuesday!🌟

From : Senior Director at a High value automotive company.👌

” I wanted to take a moment following the line start-up this morning. This was to express my thanks for Matt (Brooke) on the successful delivery of the Wheel Fit Station move project over the Summer Shutdown period.

Matt, and the team he assembled, showed outstanding dedication to safety. Also, meticulous attention to detail throughout the entire shutdown period. Please pass on my thanks to the full contracting team.

The ability to manage and contain the complexities and challenges that arose during the project (the bent torque tube and broken spring balancer) was notable. These ultimately could have risked our ability to build vehicles today.

In addition, the method by which the project was managed day to day has set a new standard for how high-risk projects are managed on site.

Please accept my thanks and know that your team’s dedication has made a lasting impression.”

It’s great to receive testimonials now and again and for this project. We are particularly grateful to our very own Matt Brooke for taking on the challenge with dedication and pride for CAS Assembly Tooling and Services yet again. Great to have him and his expertise on board.

If anyone wishes to hear more about our projects and how we can help them in any industry, not only the automotive, you are welcome for a chat. Please call Neil Evans or Jason Kane to talk about anything project management! Call on 01213271700

🌟Testimonial Tuesday!🌟

Advanced production tooling

Advanced production tooling

Advanced production tooling is necessary in your production for several reasons:


The right solution enables the production process to be carried out in the quickest and most efficient way. In turn, this boosts your productivity. The use of specialised tools allows workers to complete tasks with greater accuracy and speed. Thus reducing the time required spent on tightening threaded fasteners. The fine tuning of assembly tightening strategies within DC tools can maximise run down speed and reduce fastening time per fixing.

Advanced production tooling at CAS Assembly and Tooling in Birmingham


The use of the correct production tooling ensures that each product is manufactured consistently to the same specifications. This is particularly important in industries where products must meet strict quality standards or regulatory requirements. With error proofed production and operator guidance, faults can be eliminated. Then, the gathering of torque and process data can provide both full traceability of each tightening. This then produces a ‘birth certificate’ of the process and it various components that were undertaken.


By using specialised tools, manufacturers can reduce the cost of the manual labour element. It can also keep uptime levels to their maximum and in many cases can offer reduced operating costs and energy consumption savings. This can result in significant cost savings for the factory. Supported by reliability centred maintenance contracts tools can be kept to perform to their optimum. This then reduces expensive down time and repair costs.


Production tooling can be designed to minimise the risk of accidents and injuries in the workplace. For example, tools fitted with correct reaction devices can help prevent workers from injury and fatigue related issues. Tools can be insulated to protect from electrocution (in EV / Battery assembly). Removing air lines and cables by offering battery operated solutions can reduce trip hazards. This makes for a cleaner working environment. Correctly specified sockets and covers can protect the operator from trapped / damage fingers associated with operating tasks whilst wearing work gloves on. This is a common demand and risk in many processes / plants.

Hand-Arm Vibration Syndrome (HAVS)



Battery technology in assembly tools and advanced energy efficient DC solutions reduce energy costs associated with tooling vs pneumatic and less advanced solutions within the market place. Sourcing equipment from companies committed to developing the most energy efficient products, who operate sustainability and focus on their carbon footprint and recycling procedures can limit the impact of tooling on the environment. Operator guidance solutions can help to reduce waste in your process and support right first time methodology, which in turn reduces your waste and subsequent carbon footprint.♻️


Overall, production tooling is an essential component of modern manufacturing processes, enabling factories to produce high-quality products quickly, efficiently, and cost-effectively.

Advacned Production Tooling at CAS


Our CAS Assembly and Tooling Account Managers extensively support UK manufacturing companies to ensure production tooling is correctly specified, kept up to date and in use with the latest technologies.

If you have any queries, please call us on 0121 327 1700. One of our team will be happy to help!

Let’s introduce John Adams!

Let’s introduce John Adams!

Let’s introduce John Adams! the team at CAS Assembly Tooling and Services.

John began working for JCB back in 2004 and in 2007 joined the ‘Manufacturing Engineering’ team. This is where he met a certain Sales Manager who went by the name of Neil Evans!!😉

Neil Evans, Sales Director at CAS Assembly Tooling and Services became a regular visitor to JCB and they often went for a brew!🍵

During his time at JCB John was lucky enough to have worked on numerous projects in the UK and abroad. This ranged from day-to-day problem solving to the introduction of new machines to the assembly line.

Having taken voluntary redundancy from JCB in June 2020 when Covid struck, John went self-employed for a while before taking a Production engineer role in Tamworth.

When an opportunity to join CAS came about in 2022, he jumped at the chance to join the team.

✅John finally joined CAS in Feb 2023 as JCB Service Contract Manager. It’s great to have him on board with the JCB and CAS team!


During John’s spare time he can be found competing in Hillclimb and Sprint events in a Renault sport Clio197, and is a regular in the ‘Curbrough Sprint Championship’ where last year he finished 2nd in class. (Must do better!!)

When not racing, John is most likely to be found in his garage tinkering with the car in the quest to find the odd 1/10th of a second or so.

John Adams at CAS Assembly Tooling and Services, JCB Service Contracts Manager

He follows most car & motorcycle racing so to summarise if it’s got an engine he’s interested!!

John also has a retired racing Greyhound who loves to take him for a walk!🐕