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Cynergy Ergonomics Case
Studies
Ergonomic Material Handling Devices at Work
Cross
Frame Handling for Chassis Assembly Light Trucks
Operators
were loading chassis cross frame members manually into
robotic weld fixtures. The 35 pound – 45 pound cross
frames were lifted from the dunnage, carried to the weld
fixture and set into position ...
Engine Block Handling Lift Assist Inspection
on Machining Line
A Midwest
auto manufacturer utilizes an on-site foundry to cast
and manufacture their engines at the assembly plant.
During the machining process, the engine blocks travel
on powered conveyors between the ...
Aluminum Wheel Handling Lift Assist for
Palletizing
A Midwest
wheel manufacturer was handling 40 lb. aluminum wheels
by hand, palletizing them from a conveyor. A system was
needed to alleviate the repetitive stress injuries
occurring to their operators during this process.
Pallet Handling Vacuum Lift Assist Adjustable
Lifting System
Manufacturer of refrigeration units utilizes a wood shop
work cell to manufacture the custom pallets required for
their specific product. A new model of refrigeration
unit required pallets that were over 7 ft. long ...
Sheet Handling Vacuum Lifting Ergonomic Case
Study
An East
Coast custom metal processing facility handles sheets of
nickel, copper and magnesium throughout the shearing,
cleaning and coating processes. After applying a
protective coating, these sheets are conveyed ...
Industrial Manipulator Arm Retrofit Cynergy
Ergonomics Case Study
A 1980’s
vintage glass handling manipulator had been taken
off-line and out of service due to parts availability
problems. The basic raise, lower and tilt functions were
operational; however, the components for the vacuum ...
Panel Lifter Turning Cooler Counter Tops for
Inspection and Assembly
During the
cooler manufacturing process, counter tops go through a
foam injection insulation process. After the foam is
injected, the countertops need to be lifted and rotated
180° for cleaning and inspection, then rotated ...
Pharmaceutical Drum Dispensing Station
Lifting Handling Solution
Due to the
design of blister packaging machines, operators at a
pharmaceutical manufacturer were required to hand-scoop
caplets from drums while standing on an elevated
platform. This required repeated trips ..
Air Conditioner
Coil Handling Condenser & Evaporator Lifting for Assembly
Due to a
change in EPA Efficiency Requirements, industrial HVAC
equipment manufacturers have been required to increase
the efficiency of their units which has led to an
increase in the weight and size of the condenser and ...
Aircraft Manufacturing Assembly Handling Stringer Insertion
System
Composite
aircraft stringers require a rigid handling system to
transport the stringer and compactor assemblies from the
forming station to the mandrel. The stringers are 40 ft.
long, weigh 15 lbs. and are extremely flexible. ...
Foundry Slag
Skimmer for Steel, Iron and Other Molten Metals
Foundry
requires a device to assist operators in removing slag
from a scrap melt furnace. The process involves skimming
the slag, removing it through a door and dumping into a
bucket as well as manipulating the scrap in the ...
High Speed
Sack and Bag Handling System for Pharmaceutical Dispensing
Pharmaceutical manufacturer requires sacks and bags of
various sizes and construction materials to be
de-palletized and dumped into a hopper. This process
must be performed by a single operator requiring zero
physical ...
Manual Roll
Handling Carts with Powered Lift Pitch Grip for Label
Handling
Brewery
bottler requires a system to lift and rotate rolls of
beer bottle labels and insert them onto an unwind
spindle. The rolls arrive in the workstation area in a
core-vertical (eye to the sky) presentation, must be
lifted and ...
Peck Aircraft
Drill Motor Manipulator Wing Skin Drilling Safety
Improvement
Aerospace
industry operators required a device to assist operators
in the handling and manipulation of Peck drills during
the set-up process for wing skin drilling. Operators
were manually carrying the 45 lb. drills up ladders ...
Roll Around Shaft
Positioner for Printing and Converting Roll Materials
The
printing, converting and roll-handling industries
utilize 70 lb. – 100 lb. shafts to suspend rolls of
labels during the unwind and rewind phases of the label
printing process. The shafts are typically 4’ – 5’ long
and operators ...
Targeting System
Positioner for Infrared Guidance System Calibration
Defense
contractor requires a device to accurately position a
black body targeting device for calibration of infrared
guidance systems. Equipment is utilized in a clean room
environment with a single phase AC power supply...
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