Products from the Overhead Alliance Provide Ergonomic Solution for Metal Fabrication Facility

One of the benefits of using overhead lifting systems is to increase workflow throughout a plant which in turn lowers production costs. The following case study illustrates the features and benefits overhead lifting provided a metal fabrication facility that:

• Cut production costs by a third
• Provided a secure and clean alternative to forklifts
• Provided mobility across multiple work stations

Application Overview
A 10,000 square foot metal fabrication facility in central Pennsylvania specializes in assembling and fabricating steel bases that are used to support printing presses in large print facilities. After being in business for two years, the company president re-evaluated the fabrication workflow, looking to lower production costs in order to stay competitive.

Problem
The fabrication process involved part assembly and welding that took place at individual work stations throughout the facility. Assemblies could weigh anywhere from 900 lbs. to 1,500 lbs. Originally, jib cranes mounted on the warehouse support columns were used by workers at each station. The jib cranes were effective for work done within an individual station, but did not provide the ability to move an assembly to the next stage of fabrication. The company's first solution to this problem was to use forklifts. While the forklifts did provide mobility, they ended up becoming a safety hazard to the employees, and also introduced a significant amount of grease that was transferred onto the product. This grease had to be removed before shipping.

Solution
The problems presented by the use of forklifts lead the president to seek a more effective and secure solution. Looking to bring in an expert, he contacted a local material handling specialist to visit their site and study their fabrication workflow. The specialist spent an entire day observing the workflow and came to the conclusion that a Workstation Bridge Crane would add immediate value. After listening to the solution, the president decided to invest in a 2,000lb. capacity Workstation Bridge Crane. Once installed, the system had a runway length of 110', covering a majority of the fabrication process. The dual 20' bridges allowed workers using an overhead hoist to move assemblies effortlessly along the smooth enclosed track bridge crane.

After two months of service the company once again re-evaluated their fabrication workflow and found that through the inclusion of a Workstation Bridge Crane, they were able to cut their production time by a third. Not only was their efficiency increased, but more importantly, their workers were more secure. A Workstation Bridge Crane was a perfect ergonomic solution.

Three Material Handling Industry of America (MHIA) Industry Groups—The Crane Manufacturers Association of America (CMAA), Hoist Manufacturers Institute (HMI) and Monorail Manufacturers Association (MMA)—formed the Overhead Alliance in 2008 to promote the crane, hoist and monorail industries as alternative lifting and moving solutions that can reduce accidents, improve workplace health and safety, reduce product damage, improve workflow, lower costs and reduce environmental impact.

To learn more and to download a brochure on the benefits of overhead material handling, visit www.OverheadAlliance.org.

CMAA, HMI and MMA are affiliated trade associations of Material Handling Industry of America (MHIA). MHIA is an international trade association that has represented the material handling & logistics industry since 1945. MHIA members include material handling and logistics equipment and systems manufacturers, integrators, consultants, publishers, and third party logistics providers. Member companies come from all areas of material handling and various parts of the world, making MHIA a strong national and international representative for the material handling industry. Much of the work of the industry is done within its product-specific Industry Groups. The association also sponsors trade events, such as ProMat and NA 2010 to showcase the products and services of its member companies and to educate industry professionals on the productivity solutions provided through material handling and logistics.

Contact: Carol Miller, Vice President of Marketing & Communications, Material Handling Industry of America (MHIA) (704) 676-1190/800-345-1815.

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