The Challenge: Addressing Ergonomic Strain and Process Bottlenecks
A major component supplier for commercial lawn equipment faced a critical operational inefficiency following the installation of a new press brake. The facility needed to form heavy sheet metal into mowing decks ranging from 42 to 72 inches in width.
The logistics of the operation presented significant hurdles:
- Material Specifications: The pre-cut metal sheets were 7 to 10 gauge steel, weighing between 40 and 125 pounds.
- Manual Handling Limits: The sheer weight and dimension of the sheets required two operators to manually lift, stabilize, and position the load.
- Complex Manipulation: The fabrication process required three distinct bends. Between each actuation of the press brake, the operators had to physically rotate the sheet 180 degrees and reposition it, a movement that was difficult to synchronize manually.
This manual workflow resulted in a cycle time of approximately six minutes per unit, capping production at a mere 3 units per hour. The physical strain led to operator exhaustion, and the requirement for two workers per station severely inflated labor costs.
The Solution: Intelligent Assist Devices (IAD) vs. Robotics
The engineering team initially explored robotic automation but ruled it out due to high capital expenditure and the inability of traditional robots to provide the tactile control necessary for precise part positioning.
The optimal solution was identified as the Gorbel Easy Arm® Intelligent Assist Device. Specifically, the facility deployed a freestanding Easy Arm® Q model featuring:
- Capacity: 330-pound lifting limit to easily accommodate the 125-pound maximum load.
- Reach: A 14-foot span with a 10-foot height under the boom to cover the work cell.
- Custom Tooling: Integrated magnetic grippers from Industrial Magnetics.
- G360™ Collector: A swivel assembly allowing continuous rotation without cable tangling.
The Execution: "Float Mode" in Action
The implementation of the Easy Arm® transformed the workflow from a two-person struggle into a streamlined, single-operator task. As observed in the project video, the operator engages the sheet metal using the custom magnetic tooling.
Once lifted, the operator utilizes the Easy Arm’s "Float Mode". This feature creates a weightless sensation, allowing the operator to guide the heavy metal deck into the press brake with fingertip precision. The video footage highlights the efficacy of the G360™ collector; after the first bend, the operator spins the floating metal sheet 180 degrees in mid-air to prepare for the second and third bends without ever setting the load down.
The Result: 500% Production Increase
The integration of the Easy Arm® yielded immediate and quantifiable improvements in productivity and safety:
- Throughput Velocity: Production surged from 3 decks per hour to 15-20 decks per hour—a 500% increase.
- Cycle Time Reduction: The time required to complete three bends dropped from six minutes to two minutes.
- Labor Optimization: The process now requires only one operator, freeing the second worker for other value-added tasks.
- Ergonomics: Operator fatigue was virtually eliminated. As the Senior Manufacturing Engineer noted, "Now we can do 15-20 pieces per hour with just one operator who doesn't get exhausted at all".