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 (requiring the operators to lean over and position the load in front of them). This work cell was a chronic source of back strains and shoulder related injuries.
A high speed servo drive, PLC controlled lifter incorporated with magnet-based, pneumatically controlled end tooling was installed into the work cell. The design enables the operators to pick from all layers of all dunnage racks and set into the weld fixture without bending, reaching or lifting the load. After initial training, tact times were maintained. Additionally, the system is designed to handle multiple cross frames simultaneously when new dunnage designs are completed.