The Challenge: Overcoming heavy legacy systems
The quality of a product often reflects the efficiency of the production line. Snap-On operates a manufacturing facility in Algona, Iowa, where they build high end tool storage. This factory produces items ranging from small chests to 12-foot long units used by performance racing teams. To keep up with demand, the facility layout relies on overhead cranes to support the manufacturing process. Mike Rahe, a manufacturing engineer, explained that the cranes primarily support air balancers and gun welders.
Historically, the plant used in-house built I-beam bridge cranes and Spanmaster I-beam jib cranes. These legacy systems caused trouble. The heavy I-beam style was bulky and difficult to move. These structures did not offer flexibility for future changes. Workers had to use significant physical effort to maneuver the suspended tools. This led to fatigue and a higher rate of shoulder and back injuries.
The Solution: Aluminum bridges and enclosed tracks
Snap-On spent 14 years replacing all I-beam and jib cranes with Gorbel work station cranes. They chose lightweight aluminum bridges. By switching to enclosed track work station cranes, the company reduced the force needed to move tools. This change addressed worker fatigue and injuries and also increased productivity. The enclosed track design prevents dust from gathering on the rolling surface. This ensures smooth movement for precision welding.
The Execution: Precision on the factory floor
In the production environment, the Gorbel systems are integrated to provide overhead support. Ceiling-mounted bridges span the assembly bays. This allows workers to move heavy gun welders with very little effort. The aluminum bridges respond immediately to the operator. This eliminates the jerking motion common with heavy steel I-beams. Snap-On scaled this solution over time by adding modular components.
The Result: Measurable gains in safety and output
The shift to Gorbel produced clear results for the workforce. An ergonomic study by the Rochester Institute of Technology found that work station cranes increased productivity by an average of 27% over I-beam cranes. Rahe noted that the systems work much smoother and have reduced shoulder and back injuries enormously. The facility also uses the flexibility of the modular components to modify the workflow as products change.