The Challenge:
Tiffin Motorhomes, a manufacturer of motor homes based in Red Bay, Alabama, faced production bottlenecks. The assembly process for electric slide-out components, known as diving boards, relied on manual handling and forklift use. Operators frequently experienced downtime, sometimes waiting 45 minutes for a forklift to move these components. This reliance on forklifts for positioning slowed production and introduced safety risks and physical strain, which went against Tiffin's goal of an efficient production environment.
The Solution:
To overhaul these material handling processes, Tiffin turned to Gorbel to implement an ergonomic solution. The company chose the Gorbel Free Standing Work Station Bridge Crane, a system featuring a 1,000 lb. capacity paired with an electric chain hoist. This choice was strategic. The system provides superior load positioning through its rigid runway design, which prevents the crab-walking or binding seen in traditional bridge cranes. By removing the reliance on forklifts, the system provided the control needed to guide the diving boards into position with minimal effort.
The Execution:
Installation of the free-standing system required no stress on the building overhead structure, a benefit for the Tiffin facility. The bridge crane allows workers to maneuver the components across the production floor. The worker manually guides the component while the Gorbel crane handles the bulk of the lifting and positioning. This interaction turns a high-strain task into a fluid motion, allowing the assembly team to maintain a consistent flow.
The Result:
The implementation yielded immediate results. Tiffin eliminated the 45-minute forklift wait times, ensuring production continues throughout the day without delays. Workers now experience less physical strain, contributing to a more productive workforce. By streamlining the handling of electric slide-out components, Tiffin has established a repeatable, user-friendly process that has inspired additional material handling improvements throughout their manufacturing facility.