The Challenge: Ergonomic risk in heavy-duty assembly
A manufacturer of hydraulic power units recently redesigned its assembly workflow to accommodate a new product line. This specific work cell required operators to pick and place components throughout the assembly process. The units were heavy, weighing up to 2,000 lbs, and awkwardly shaped. These factors created significant handling difficulties.
The company identified a risk where manual handling or improper equipment could lead to workplace injuries and lost time accidents. While forklifts were initially considered, they presented a logistical bottleneck. In a fast-paced assembly environment, the limited mobility and large turning radius of a forklift would slow production cycles. Furthermore, the capital expenditure and ongoing maintenance costs of a forklift fleet offered a poor return on investment.
The Solution: The Gorbel aluminum bridge advantage
Based on a history of success with Gorbel equipment, the engineering team bypassed mobile floor equipment. They chose a permanent overhead solution instead. This configuration consisted of two Gorbel Free Standing Work Station Bridge Crane Systems.
To maximize the work cell footprint, the team installed two 19-ft side-by-side systems supported by 63-ft steel runways. By using an aluminum bridge within a steel runway framework, the manufacturer achieved a 2,000 lb capacity. This setup reduced the dead weight the operator must move. The hybrid approach uses the strength of steel for long runway spans and the ergonomics of aluminum for the moving bridge. This ensures low start-up and rolling resistance.
The Execution: Precision engineering in action
The installation used a common center post design. This allowed both 19-ft bridges to operate side-by-side without many vertical supports. The workflow uses a push-button lifting operation. Operators use specialized below-the-hook attachments to secure the hydraulic units and glide the aluminum bridge along the enclosed track runways.
The enclosed track design prevents dust and debris from accumulating on the rolling surface. This ensures that 2,000 lb loads move easily even after thousands of cycles. The rigid runway design eliminates the swaying common in less sophisticated systems. This allows for accuracy during the pick and place phase of assembly.
The Result: Zero accidents and higher throughput
Since the integration of the Gorbel systems, the facility has reported zero lost time accidents in the hydraulic assembly cell. By moving the lifting process overhead, the company reclaimed floor space previously used for forklift paths.
The ergonomic ease of the aluminum bridges has sustained production speeds without operator fatigue. The manufacturer balanced high-capacity industrial lifting with the precision required for complex hydraulic assembly. This project demonstrates that ergonomic investment supports operational goals.