A major pump manufacturer was looking for a safer, more efficient way to load adapter castings weighting up to 70 lbs. onto the chucks of their twin spin-dle-milling machine. First, they had to identify the potential hazards and prob­lems to ensure worker safety, including the following:

.                       • The position operators had to main­tain to carefully place the castings on the chuck, putting them at higher than acceptable risk for injury;

.                       • The costly soft-jaw chucks in the milling machines were repeatedly damaged when castings were put down with too much force; and

.                       • Operators were losing valuable cycletime waiting for their air balancers to bleed pressure before placing the load.  

Ergonomic Solution: The manufac­turer replaced their air balancer with an intelligent lifting device. Because this device moves with the operator and doesn’t require push buttons, switches or valves, the operator can move at a natural pace. Plus, because they don’t have to wait for it to bleed pressure like an air balancer, they reduced cycle times.

The intelligent lifting device also has the added benefit of programmable virtual limits and speed reduction points. The op­erator can lift the castings out of the bin at his natural pace, but the intelligent lifting device is programmed to sense when he nears the milling machine. It automati­cally shifts into slower speeds as the op­erator approaches the chuck, decreasing damage to the chuck and eliminating the need for costly re-cutting.

Increased Productivity: Thanks to the introduction of an intelligent lift­ing device, productivity has increased 100 percent, and they have been able to decrease their on-floor inventory by 50 percent. Plus, the operators are thrilled with the speed of the intelligent lifting device. FSM Source: The Material Handling In­dustry of America and Gorbel, Inc., maker of work station cranes that can increase productivity up to 28 percent.