The Challenge: Overcoming ergonomic hazards in plastics fabrication
For a manufacturer specializing in engineered plastic components for dump truck bed liners, the fabrication process presented a significant ergonomic and safety hurdle. The production line required the handling of large, unwieldy plastic panels (averaging 350 lbs each and measuring 4' x 10', sometimes extending to 20' in length). Due to the inherent slipperiness and size of these materials, manual manipulation was necessary to move panels on and off machinery, conveyors, and rolling tables. This forced the workforce to rely on dangerous manual lifting practices involving multiple employees. These practices created a high risk of musculoskeletal injury and inefficient, stop-and-go production workflows.
The Solution: Precision lifting with Gorbel work station bridge cranes
To mitigate these hazards, the facility implemented a 1,000-lb capacity Gorbel Free Standing Work Station Bridge Crane featuring 40' runways and an 18' bridge. This system was specifically chosen for its ability to integrate advanced automation with ease of operation. The bridge was equipped with motorized Gorbel tractor drives and a specialized vacuum lifting device. This device allowed operators to grip, lift, and maneuver the heavy, slippery panels with minimal physical effort. By transitioning to a radio-controlled, wireless system, the manufacturer successfully removed the need for direct manual contact with the materials during transit.
The Execution: Streamlined material flow
The integration of the motorized bridge crane transformed the plant floor dynamics. Operators now utilize the vacuum attachment to securely hold the plastic panels, which are then effortlessly traversed across the bridge crane system. As observed in on-site operations, the system allows for precise placement of the heavy sheets onto processing equipment. This setup drastically reduced the labor-intensive "manhandling" that previously bottlenecked production. The motorized tractor drives ensure smooth, reliable acceleration and deceleration. This movement prevents the swinging or shifting of the awkward loads.
The Result: Enhanced safety and efficiency
The installation of the Gorbel system yielded immediate, quantifiable improvements.
For safety and ergonomics, the facility eliminated the primary sources of ergonomic strain. They removed the requirement for multiple employees to lift heavy, slippery panels.
In terms of efficiency gains, the fabrication process is faster. A single person can now complete the same job that previously required several people. Consequently, the company can reallocate valuable labor to other areas of the facility.
Regarding reliability, the maintenance supervisor reported that the cranes are exceptionally reliable. They remain virtually trouble-free with simple, basic preventative maintenance routines.