Schmalz Makes Lifting Easy

Manufacturing commonly requires operators to lift and move heavy materials, which can lead to injury and fatigue. This material handling solution makes lifting a breeze.

Customer

A leading US Electronics Recycling Company.

 

Challenge

This customer wanted to reduce the possibility of injuries from the amount of lifting their operators were exposed to. This problem was leading to higher turnover in specific areas due to common complaints of lifting parts that were upwards of 120 lbs! Thus reducing the rate of production and declining morale throughout the production floor due to manual lifting.

 

Air Power Solution

The Schmalz JumboFlex 50 was able to lift the customers’ desired weights of 40-120 lbs and capturing their desired throughput goal of 60-70%. This piece of equipment utilizes a vacuum suction pump that relieves the weight of the piece you’re picking up and relieving the amount of strain on the operator’s backs. Pairing the JumboFlex with Schmalz’ Column Mounted Jib Crane, we are able to reach out 10ft and have 270 degrees of full motion!

 

Results

This material handling solution completely eliminated the customers’ problem. The Schmalz JumboFlex 50 eliminated the risk of injury for operators. This allows them to work faster, increases the rate of production, and reduces fatigue from constantly lifting heavy materials. The Section Manager stated, ” It’s not about the speed we’re able to go at, what this piece of equipment has done for us is, improve employee morale and reduce turnover now that they don’t have to lift heavy stuff all day long.”

 

 

Assembly Made Simple

In this case study, Air Power builds a custom integrated system that makes Ergonomics, Safety, and Quality simple with a team effort.

Customer

This customer is a supplier in the Truck and Bus industry.

Challenge

The customer needed to outfit a new work cell assembling large metal components. First, the weight of the fully assembled sub-build components exceeded 1000 lbs. requiring a high weight capacity work table. Secondly, the height variation of the operators presented ergonomic issues from shift to shift to ensure each operator performed his necessary tasks at optimum work heights for ergonomics and safety. Thirdly, target torque for each component exceeded the safety threshold for handheld tooling, 69 ft/lbs, and 135 ft/lbs. requiring a torque management solution to be included in the overall work cell build. Lastly, the components needing to be torqued are deemed quality critical, requiring all data for the fasteners to be documented to ensure a proper build.

Air Power Solution

Air Power included the following in our solution; a 2000 lbs. capacity adjustable height pneumatic Presto lift table, a GCI torque reaction arm, and a Cleco MPro 300 controller with right angle NeoTek tool. We were able to meet the high weight by working closely with Presto directly to customize the adjustable height scissor lift table. GCI was able to build a custom torque arm to provide the needed reach and vertical travel while managing up to 240 NM of torque reaction. We were able to mount the torque arm directly to our adjustable height table, allowing the entire work station to adjust to ideal work height for any given operator. All of this wrapped around the brand new Cleco 300 controller with NeoTek right angle tool allowing for a precise fastening solution meeting and exceeding the quality critical parameters required. The Cleco 300 also allows our end-user to monitor, collect, and organize critical data to ensure they every unit out the door is a quality part.

 

Assembly

Results

Air Power’s solution addressed all of the problems the customer faced with this assembly process. The Presto Lift table allows the operator to adjust the height of the entire system to eliminate and bending and back strain. The GCI torque arm holds and handles the Cleco right angle NeoTek tool. This eliminates any lifting and hand or wrist injury from handling a torque tool. Lastly, the Cleco mPro 300 controller gave the customer the ability to ensure perfect quality with every assembly.

 

 

Get the Perfect Ratio with GEMS 2K

 

When it comes to mixing paint, accuracy is the key to achieving a high-quality finish. In this case study, we discuss a 2K solution that helped this customer perfect their process and save tons in production costs.

Customer

 

Manufacturer of roadside transformers.

 

Challenge

 

This company has a small parts booth for primer and topcoats. The operator had to manually mix two types of epoxy and one urethane. Each day he had to spray all three colors from the same hot pot system. The color change process was a major problem as the different parts to be sprayed were not batched. This caused a lot of waste of paint and solvent. The other concern was being off ratio and parts not curing properly. This was a major cost to the company. They also had a large booth that sprayed the finished transformer. They had to utilize the same paints and this process had the same problems. If the large transformer was off ratio, they had to sand the paint off and repeat the entire process. This proved to be a very expensive problem.

 

Air Power Solution

 

Air Power proposed to install a Carlisle GEMS 2K mix system for each color. We also put in a pump system to pump and circulate all paints to the mix machines. The catalyst was dispensed to the machines from 5-gallon pressure tanks. The 55-gallon drums of paint each had an agitator in them to keep paint in suspension to maintain viscosity. By having a machine for each color there was no color change or off ratio problems.

 

Results

 

The Air Power Solution eliminated the need to hot pot in tanks. Since each color is mixed on demand; this system provided a major labor savings. There is no paint waste and the newly established process saves about 2 to 3 hours per shift as compared to manually formulating and mixing paint. The solvent usage was greatly reduced as there was not a tank to clean each color change. This solution has been able to speed up production on all three shifts. Our technical group and installers were able to put the system in place without impeding the customer’s production runs.

 

GEMS 2K Mix System

 

 

Ingersoll Rand Improves Ergonomics

Manufacturing facilities in today’s competitive market strive to reduce the ergonomic impact of their operators. In this case study, we will discuss the importance of recognizing every company’s desire to improve ergonomics and reduce injuries.

Customer

A global manufacturer, producing products for the heavy truck and bus industry.

Challenge

Operators were manually lifting 40-150lb truck hubs and rotors to palletize for their shipment to their end-users. The operators were refusing to use their current lifting method as it was slow and delayed their production during the days shift resulting in reduced throughput per operator per shift.

Air Power’s Solution

We proposed they moved to a single large floor supported structure with multiple bridges, air balancers, and welded end effectors. This allowed multiple operators to use a single structure with each having their own ”bay” containing a bridge, balancer, end effector combo. This gave everyone the room they needed to load pallets as well as the lifting method that allowed the ergonomic impact to be reduced while still allowing the productivity of the manual lifting application. The air balancers’ speed and the pendant control allowed the operators to move at the speed they deemed fit for each application and individual operator preference.

Result

Currently, we have installed 5 large lifts in this facility with more now being planned at their sister facilities, leading to many overall ergonomic improvements.

Ergonomics

Ergonomics - Ingersoll Rand

 

 

 

 

 

 

 

 

 

 

 

Learn More about Ingersoll Rand 

Monti 3D Powder Coat Line Walkthrough

 

Monti 3D Powder Coat Line Walkthrough

 

Air Power Manufacturing Solutions teamed up with GAT Finishing Systems, Rohner Powder Coating Booths and Gema Powder Application Equipment to create a unique automated powder coat line that can process large and small parts quickly and efficiently. Monti Inc’s new powder coat line was built with quality results in mind, with the capabilities to meet the strictest specifications.

This new 20,000 sq. ft. powder coating facility is located in Greenwood, SC. This powder coat system has been tested to exceed 1,000-hour salt spray, tested per ASTM B117 meeting requirements of UL-1332 including ASTM D7091-05, D1654-08, D610-01, D714-02. This automated powder coat line can handle parts up to 2 ft x 4 ft x 8 ft. The batch powder coat system can handle parts up to 8 ft x 8 ft x 14 ft. Either line can paint any color. The system currently has lots of capacity to offer. With regard to throughput, it paints a 1-3/4” X 7” part and can powder coat and package 36,000 of these during 1 shift.

Monti Powder Coat Line

 

Source: Monti Powder Coating

Gema Meets the Challenge

Manufacturing facilities in today’s competitive market strive to produce the highest quality product. In this case study we will discuss the importance of recognizing every company’s desire to produce a premier product with the highest first place transfer efficiency.

 

CUSTOMER

A Custom Fabricator, producing products for the truck & and Bus industry

 

CHALLENGE

In order to distinguish them within the marketplace, the current manufacturing process needed to meet customer’s mil specs. Their current Powder Units were not producing enough Mils per MFG spec with a Quality finish. Examination by quality control engineers revealed that they were getting back ionization and orange peel when applying more powder and second coats. They determined that each operator had different settings and too much powder output. In addition they did not understand current and voltage and how they relate to a quality finish and high transfer efficiency.

 

Powder Coating Defects

SOLUTION

In partnership with the customer, Air Power implemented an Gema OptiFlex 2 manual powder unit. The unit comes with 3 presets: 1: Flat Parts, 2: Recess/complex parts and 3: Recoat mode. In addition these cannot be changed by the operator and allowed ease of use with a simple repeatable process. The Patented Digital Valve control allowed for consistent precise powder output, powder savings, and reproducible coating results.

 

Gema Powder Process

RESULTS

Currently, the customer is meeting their mil spec and producing repeatable results and has increased there transfer efficiently that has provided a 1 year Return on equipment investment.

 

 

High Performance. High Quality.

 

Quality control and consistent finish were big goals for a manufacturer of ceramics. This case study delves into how Air Power put together a multifaceted solution to meet this customers finishing needs.

CUSTOMER

This customer is a manufacturer of ceramic products.

CHALLENGE

The customer was operating on an outdated system with no quality control measures in place. There were no gauges to regulate the air and fluid pressure of the system. There was not a way to manage the quality of the finish during the paint process. The system had one huge hose bundle with no way to identify which fluid was delivered via each hose. The only operator who could manage the system was nearing retirement.

SOLUTION

Air Power installed a paint system with a control panel that allowed for individual control of each automated spray gun. This system included large liquid filled gauges for display of air and fluid pressures to allow the customer to manage the system. Our engineers designed a system with neatly organized, color coded hoses for each gun to simplify production management. This allowed new operators to easily perform maintenance on the paint line.

RESULTS

The system changes made succeeded in simplifying this system. This has made it easier for all the operators to learn how to manage, operate, and maintain the paint line. The control panel gave the customer a simple, safe way to start and stop seperate spray guns during the process. This has allowed the customer to control the paint process and usage of paint. This opened the door for more focus on quality control and saved paint and production time.

 

Ceramic Manufacturer

 

Silicone Drum System Saves Money

 

Manufacturing facilities in today’s competitive market strive to produce the highest quality product. In this case study we will discuss the importance of recognizing every company’s desire to produce a premier product.

Customer

Leading Global Manufacturer of Display Refrigerated Cases Systems

Air Power’s Solution

In partnership with the customer and the silicone material supplier (Ellsworth Adhesives), Air Power offered a solution by using 3 ea.  Graco 55 gallon drum packages. These drum packages will replace manual and battery operated caulking guns. By going to bulk drums vs expensive tubes customer will reduce silicone cost by 30%. Customer purchases over 1 million dollars per year in silicone. Drums are placed near three assembly stations throughout the plant. Material fluid hoses are festooned 14 feet over head at each operating station to eliminate dangerous trip hazards.

Result

By converting from caulk tubes to bulk 55 gallon drums customer will reduce RTV silicon by an estimated cost by 30%. Each Graco 55 gallon ram drum package features Graco Data Trak. The Graco Data Trak features a light tower located on the 55 gallon ram package. The light tower will alert the operator with a signal showing drum is low on material or empty.

Increased floor space by eliminating cartons of tubes placed on wood skids near each operating station. Increase production time by elimination to open cartons of tubes of silicone and place tubes into manual caulking guns.

Eliminate the need to have batteries charged. Eliminate the cost of replacing battery charged caulking guns.

 

NEW Binks AG-364 Airless Spray Gun

 

Carlisle Fluid Technologies made an innovation in transfer efficiency when they introduced the new Binks AG-364 Airless Spray Gun. This gun achieves high quality results faster, easier and more efficiently than other spray guns on the market.

Available in dead head or recirculation manifolds, this high-quality airless spray gun helps eliminate excessive paint waste and lengthy cleaning time. The AG-364 accomplishes ultimate transfer efficiency, resulting in: reduced overspray, cleaner machines and reduced applied coating cost per part.  Softer, high-integrity fan pattern also allows for the consistent application of materials to detailed profiles and surfaces. The tip holder indexes 45 degrees with insert and is completely adjustable without insert. The versatility of tips utilized on the AG-364 allows for application of multiple wood finish materials.

As a member of the proven AG family, the AG-364 makes it easy to upgrade from air-assisted airless equipment. It utilizes the same pumps, fluid lines, regulators and fluid pressure ranges for a
seamless transition.

 

CFT BINKS AG-364

Specifications

 

CFT BINKS AG-364 SPECS

 

 

Increase Transfer Efficiency

 

Challenge

Customer was looking to improve transfer efficiency on their automated spindle machine spraying primer on various size metal housings.   The existing system utilizes one spray gun set a considerable distance from the parts.  This causes excessive overspray and waste.  Customer also wanted to go from using 55 gallon drums to 5 gallon pails due to settling and solvent flash off in the primer.  The 55 gallon drum sits for around 4 months.  The viscosity needed to be regularly checked and adjusted.

 

Before Before 2

 

 

 

 

 

Air Power’s Solution

Equipment utilized – Graco fixed automatic spray guns coupled to a Graco dual regulated pressure pot with agitation.  All controlled via an Air Power custom designed pneumatic control panel for system optimization and performance.

Air Power, Inc. proposed replacing their single gun setup with two guns.  These guns will be mounted on mounts that can be adjusted to effectively cover the various size parts.  This will minimize the amount of overspray and improve the transfer efficiency of the system.  The controls for this system will be contained in a centralized control box.  Fluid supply will utilize a 5 gallon pressure tank.  This will allow the operator to place a 5 gallon bucket of primer into the tank.  This system will be enclosed to minimize solvent flash off.  This will help improve the consistency of the coating as it will not need to be constantly adjusted.  The paint supply will also be exhausted in roughly a week now.  This will allow fresh primer to be sprayed, also improving consistency.

 

Results

  • Customer experienced increased transfer efficiency which saved them money by minimizing the amount of overspray and waste. It also reduced the amount of filtration they were purchasing due to the reduced overspray saving them time and money.
  • Customer reduced solvent flash off due to the switch from 55 gallon to 5 gallon pail saving the operator time from adding additional solvent to the 55 gallon drums.

 

Air Power Solution Air Power Solution