The Challenge:
For Sellick Equipment, a manufacturer of all-terrain forklifts, operational efficiency was severely hindered by the constraints of their legacy facility. The manufacturing environment was plagued by significant physical limitations, including restrictive ceiling heights and a grid of structural columns spaced every 15 feet. These obstacles severely limited floor space utilization and hampered the movement of products through the assembly process. Consequently, the team was forced to rely on heavy, cumbersome fork trucks to navigate the floor to assist with basic assembly tasks. This created safety risks and significant production bottlenecks.
The Solution:
Recognizing the need for a more ergonomic and efficient solution, Sellick Equipment management conducted extensive research, testing various overhead systems at major industry events such as FABTECH USA and FABTECH Canada. Among the options, Gorbel emerged as the clear leader for ease of use. Sellick reported, "When it came down to ease of use, it was by far Gorbel; there was no one that was even close to having a system that worked as well or as easily as the Gorbel system."
The company chose a comprehensive integration of Gorbel free-standing work station cranes. The configuration required two free-standing workstation cranes in the fabrication area to service milling machines. They also installed an 8-bay free-standing workstation crane system to service 16 welding cells. Finally, a 140-foot free-standing workstation crane equipped with four aluminum bridges, including two 2-ton and two 1-ton units, covered the assembly line.
The Execution:
The installation transformed the workflow by eliminating structural interference. In the new, open-floor-plan facility, the Gorbel cranes provided seamless, unobstructed coverage over the 140-foot long and 20-foot wide assembly line. Operators can now manipulate the forklift components with precision. They move them through the assembly sequence without the need for fork trucks. The integration of 2-speed hoists allows for precise part positioning, while the aluminum bridges remain stable under load. This stability prevents any unwanted drift or slide.
The Result:
The implementation of the Gorbel system resulted in immediate productivity gains. By removing floor-based movement restrictions, the company reclaimed valuable square footage for organized part storage. This change smoothed out workflow processes. Assembly operators can now maneuver products with a single finger. This capability drastically reduces physical fatigue and the time required to complete each unit.