The client, a local granite countertop supplier, was purchasing a new machine to custom cut their client’s countertops. Their existing workstation crane and hoist system didn’t allow the flexibility they needed to maneuver the granite into the proper position.
After on an onsite review, it became clear that a custom designed crane and hoist system was needed for the project. Account Manager Justin Kuhn and Application Specialist Chris Nelson were able to custom design a 2 ton Gorbel crane and 1 ton Harrington Hoist system that allowed the power and flexibility the client needed.
The Air Power solution is working perfectly and this will likely be the last crane the customer will ever need. The added bonus was an annual maintenance plan for all of their existing cranes and hoists. The ability of our team to not only immediately identify the issues, but to also have the technical skill to design a customized system leads to the perfect Manufacturing Solution.
Once again the tremendous knowledge and experience of our Account Managers and Application Specialists not only solves the issue at hand, but creates a long term customer.
This case study was presented by Baltimore Key Account Manager Lorne Rickert.
A counterweight was attached to a turntable before the Hydraulic Motor which “keys” the turntable to the frame, located underneath. The counterweight caused the turntable to rotate until it was so far off balance that the Turntable with Counterweight fell off the Frame, coming to a rest about 2’ from a Team Member! This posed a significant safety hazard, as well as, assembly frustration to the onsite engineering team.
Air Power Solution
Air Power utilized an Ingersoll Rand QX Power Tool and Sturtevant Richmont Digital Wrench to positively confirm that all of the tightening’s have been completed before the Counterweight can be installed.
Air Power’s Engineering Team, Michael John and Jesse Bryant, designed a “Lifting Sling Lock” device that will not release the lifting sling for the counterweight until the Tightening’s are complete – a Poke Yoke control to insure safety. This “Lifting Sling Lock” is utilized in conjunction with the I/O output of the Ingersoll Rand QX and the STR Digital Wrench, thus eliminating the safety hazard of a dropped counterweight. The Lifting Sling Lock will only unlock once all tightening have been positively confirmed, removing a safety hazard and improving overall production quality.
Flooring Manufacturer was looking to increase pass yield coverage while spraying their Waterborne Topcoat on their flooring. Their old process was using two Automatic Anesta Iwata air spray guns.
Air Power Solution
Through Air Power’s partnership with Carlisle Fluid Technologies we were able to offer the customer a solution by providing two Binks Automatic AG-364 Airless Spray guns fed by a Binks MX Series Pump. The results were tremendous.
The Customer Experienced the following benefits:
- Increased Pass Yield Coverage by around 40% on average.
- Reduced coating use by around 50%.
- Reduced clean up with the reduced amount of over spray
- Improved coverage on edges and profiles, eliminating the shadow effect.
- Elimination of CFM air usage.
The above benefits save the customer TIME and MONEY!
An axle manufacturer has had ongoing issues with accurate filling of gear oils in axle hubs and center differentials due to the operator having to manually select the oil dispensed along with the quantity of oil being dispensed into a given axle. There would be issues with the operator selecting the incorrect oil or volume of oil which often resulted in quality issues of an axle or batch of axles. There was no way to confirm which oil and volume of oil was dispensed into a given axle, which operator did the dispensing on a given axle. All data was on the build sheet for the axle and it was the responsibility of multiple operators and quality technicians to ensure it was filled correctly. All build sheets would have to be read by operators on both sides of the line, then they would have to select the correct oil and volume of oil based on what they read or thought they had read. Quality tracing was extremely difficult using this method. Oil spills and drips were also extremely common, leading to waste and safety concerns
Air Power Solution
Multiple Graco ProDispense systems have been introduced to the facility to eliminate these issues by utilizing advanced technology and programming to ensure error free selecting and filling of fluids. The facilities engineering team will be integrating the ProDispense into their existing PLC’s with new HMI’s which will contain each axles information and location in real time on the line. This will allow each axle’s build sheet to be loaded into the system. By using the axle’s build sheets in the system each operator will touch each axle’s hub or center diff on the HMI which will automatically select the correct oil and oil fill volume for that particular component which will have been preloaded into the PLC and ProDispense by the engineering team. Once the location on the axle has been touched on the HMI the ProDispense will have the appropriate recipe selected via the PLC and the system will illuminate an LED light next to the correct hose reel which contains the appropriate oil. The operator will then unwind the hose reel and dispense valve and insert it into the appropriate oil fill port. Once that is done they will touch the start button on the HMI which will trigger the ProDispense to fill the appropriate volume into the axle. This information will be recorded in their network and will be easily traced back to the axle, oil used and operator performing the fill for traceability. The ProDispense will accurately dispense the correct oil every time within +/- 1%. This will reduce rework, defects and axle failures for the end user. We are utilizing no drip valves to ensure drip free operation to reduce waste and spills to improve safety at the line sides.
The ProDispense allows for accurate selecting, fill tracking, capturing data associated with each fill to prevent defects, failures, waste and improves safety and accuracy of the entire filling process. Repeatability of the process with operators both new to the line and veterans is much improved as each selection is now automated by the system.
A local chemical supplier has to manually inspect and repack bags of their product which has been requiring manually lifting, inspecting and repacking of 60lb bags from one pallet to another. This has introduced an ergonomic liability for the manufacturer and has opened the door for multiple operators to injure themselves. The answer has been to station multiple operators (5-6) in the area to tackle this problem. They rotate lifting, repacking, and inspecting to limit the risk and keep everyone safe.
Air Power Solution
A custom solution provided by Air Power consisting of Schmalz vacuum lifters, Gorbel jibs and Presto P3 spring lift/turntables. The one handed bag lifter allows the operators to effortlessly lift the bags after inspection to be repacked on the next pallet. The Gorbel jibs allow them to reach multiple pallets from a single vacuum lifting system. The P3 turntables allow the operator to maintain a very small footprint by bringing the bags to them via the turntable rotation. It also prevents bending, stretching and reaching for bags with the vacuum lifter which reduces operator injury risk and allows the vacuum lifter to maintain a vertical lift throughout the unpacking and repacking of pallets.
What formally took 5-6 operators to complete is now completed using 2 operators with a much reduced injury and fatigue risk for the operators. They are able to alternate inspection and repacking effortlessly between them throughout the day since they are no longer manually handling the bags. The takt time of each inspecting and repacking operation has been reduced as well due to the speed and ergonomics at which the single handed vacuum lifter operates.