The Challenge:
In the heavy-duty construction machinery industry, manufacturing components as substantial as 28-foot-long bulldozer track assemblies presents significant ergonomic and logistical hurdles. A manufacturer specializing in this equipment faced a critical bottleneck. Their assembly process required these massive, 1,304-lb track pieces to be flipped 180 degrees midway through production. Workers previously maneuvered these heavy, unwieldy loads manually. This practice created a high-risk environment for injury and slowed the production cycle to an unsustainable rate. The primary goal was to design a new, safe work cell that could handle the weight, improve worker safety, and boost production capacity to 15 pieces per 8-hour shift.
The Solution:
After researching several material handling options, the company selected a Gorbel® Free Standing Work Station Bridge Crane. They chose this system for its safety, ease of operation, and cost-effectiveness. The crane cost one-third of the price of alternative designs. The final configuration included a 25-foot long, 2,000-lb capacity bridge and 6-foot, 2,000-lb capacity runways. This setup was integrated with a custom-engineered hoist and specialized tooling system designed to securely grip and flip the bulldozer track.
The Execution:
The installation transformed the manual-heavy process into a streamlined, automated workflow. In the new work cell, the 28-foot track segments roll onto a conveyor for initial assembly. Once the first side is complete, workers deploy the Gorbel® crane’s custom tooling, which features specialized grippers, to engage the track. The operator uses the crane to lift the 1,304-lb assembly, smoothly flip it 180 degrees, and lower it precisely back onto the conveyor for underside assembly. The enclosed track design ensures the bridge and trolleys move with minimal effort. This design allows operators to control the heavy load with precision and minimal physical strain.
The Result:
The impact on the manufacturing line was immediate. Since the installation, the facility has recorded zero injuries. This safety record eliminated the ergonomic hazards associated with manual lifting. Most impressively, the company met its production objective. Output increased to 15 pieces per day within the first year of operation. Workers adopted the new system quickly. They cited the intuitive control and ease of positioning as major improvements over their previous methods.