The Challenge: Balancing throughput with ergonomic integrity
Maintaining high production throughput is essential for organizational growth. A Florida-based metallurgical facility recently encountered significant operational bottlenecks within their heat treat department. As demand surged, the manual handling of hardened steel gears, which measured approximately 10 inches in diameter and 2 inches in thickness, became a critical point of failure.
An individual gear weighs less than 5 pounds. However, the established workflow required operators to lift bunches of 10 to 12 gears simultaneously to meet cycle time requirements. Manually handling these concentrated loads at high speeds created a high-risk environment for operator fatigue and musculoskeletal injury. Management recognized that traditional hoists could mitigate the physical strain of the weight. Despite this, they often failed to provide the necessary responsiveness to improve overall cycle times.
The Solution: Implementing the G-Force® iQ
To resolve these constraints, the company integrated a Gorbel® G-Force® iQ intelligent assist device with a 165-pound capacity, mounted on a Gorbel® work station crane. The G-Force® system was selected for its unique ability to combine the safety of a lift-assist device with the high-speed agility required for rapid industrial throughput.
The Execution: Ergonomic handling at speed
The implementation focused on seamless integration with existing manual processes. To maximize efficiency, the facility's engineering team custom-crafted a handling tool featuring a spindle. The operator slides this spindle through the center of a 12-gear bunch and secures the lift by hooking onto both ends of the spindle.
The G-Force® iQ boasts lifting speeds up to 200 feet per minute, or 125 fpm under load. This system allows the operator to transport the parts from the heat treat equipment to the unloading station with precision. Upon reaching the destination, the operator places the parts down and smoothly extracts the spindle. Operators have reported that the crane movement feels like a natural "extension of their arm." This creates a fluid, intuitive workflow.
The Result: Triple productivity gains
The deployment of the G-Force® iQ delivered measurable results across both safety and operational metrics. By automating the high-speed lift, the company eliminated the risk of operator fatigue while simultaneously streamlining the heat treat cycle. Within the new workflow, the facility successfully tripled its overall productivity. This change proved that high-output manufacturing can be achieved without compromising worker wellness.