Manual handling risks in heavy inspection
A turbine motor overhaul center serving the oil and gas, power generation, and military sectors faced an operational bottleneck during its inspection phase. Engines arrived for refurbishing after long periods of use. Staff disassembled these engines into components weighing as much as 100 pounds. Parts moved via conveyor to inspection stations. At these stations, operators had to manually lift and twist to position the parts on workbenches.
This physical toll caused problems. Manual lifting led to lost-time back injuries. It created a high-risk environment for the workforce. Older and female operators faced especially high strain. One operator had undergone three back surgeries in ten years of employment because of repetitive stress. Her situation showed the need for ergonomic intervention.
Gorbel freestanding easy arm
The facility installed four freestanding Easy Arm units to lower injury risk and maintain throughput. This Intelligent Assist Device combines crane strength with the responsiveness of a human arm. Several technical features influenced this choice. The articulating arm design provides a 10-foot span. This offers coverage across the conveyor and the inspection cell. Because the units are freestanding, the company completed rapid installation at the four stations without modifying overhead structures. The system allows operators to feel the load without bearing the weight. This responsiveness helps with delicate turbine component inspection.
Workflow integration
Implementation focused on the path between the conveyor and the pallet. Operators use the Easy Arm to intercept parts on the conveyor. The articulating motion moves the part into the work cell for damage assessment. Afterward, staff move the part to a case or pallet on the floor. The project changed the inspection area. Blue powder-coated units occupy a small footprint but provide vertical and horizontal reach. Operators maintain a neutral posture. This removes the lift and twist motion that caused spinal stress.
Zero injuries and workforce longevity
The Gorbel solution had an immediate impact. The facility recorded zero back injuries at these stations after installation. Now, any operator can handle every part in the cell regardless of physical stature or age. This improved staffing efficiency. The operator who previously had three back surgeries returned to work with no limitations. She stated that she would have had to retire if the company had not installed the machine.