Improvement Options for Lifting Device Team Lift Turntable

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Improvement Options for Lifting Device Team Lift Turntable

Improvement Options for Lifting Device Team Lift Turntable

Improvement Options for Lifting Adjustable Work Platforms Portable Stairs Adjustable Work Surfaces

Improvement Options for Lifting Adjustable Work Platforms Portable Stairs Adjustable Work Surfaces

Improvement Options for Awkward Postures Remove Sides of Receptacles Add Handles to Containers Workstation

Improvement Options for Awkward Postures Remove Sides of Receptacles Add Handles to Containers Workstation Cut. Outs

BEFORE Problem: Lifting castings (2 -110 lbs) out of baskets – back bent at

BEFORE Problem: Lifting castings (2 -110 lbs) out of baskets – back bent at or over 90 degrees 5

AFTER Solution: 10 lift and tilt units, three load levelers 6

AFTER Solution: 10 lift and tilt units, three load levelers 6

AFTER BEFORE COST: $2500 per lift and tilt. $1500 per load leveler. COST RECOVERY

AFTER BEFORE COST: $2500 per lift and tilt. $1500 per load leveler. COST RECOVERY TIME: Six months BENEFITS: Greatly reduced bending, lifting & reaching. Reduced strain & fatigue and increased productivity. 7 After 6 8 0 8 6 0 8 Grip Foot Total 6 Freq Opinion Before Deg Grasp Twisting Weight Position Shot Blast Frequency 8 4 2 6 42 0 4 2 4 30

BEFORE Problem – use hand dollies to manually move product 8

BEFORE Problem – use hand dollies to manually move product 8

AFTER 9 Solution: Power dollies

AFTER 9 Solution: Power dollies

BEFORE AFTER COST: $4000 COST RECOVERY TIME: 4 -8 months BENEFITS: Reduction of back/shoulder

BEFORE AFTER COST: $4000 COST RECOVERY TIME: 4 -8 months BENEFITS: Reduction of back/shoulder injuries. Increased productivity After 2 10 6 6 0 2 0 0 Grip Foot Total 6 Freq Opinion Before Deg Grasp Twisting Weight Position Material Handling Frequency 6 0 0 4 28 0 0 0 2 6

BEFORE 11 Problem – pushing pattern cart caddy

BEFORE 11 Problem – pushing pattern cart caddy

AFTER 12 Solution – use mule to move carts

AFTER 12 Solution – use mule to move carts

BEFORE Problem – sanding 500 -1000 castings (2 -10 lbs) with many hand movements

BEFORE Problem – sanding 500 -1000 castings (2 -10 lbs) with many hand movements 13

AFTER 14 Solution – robotic arm is used to grasp the casting

AFTER 14 Solution – robotic arm is used to grasp the casting

BEFORE AFTER COST: $176, 000 COST RECOVERY TIME: 6 -12 months BENEFITS: Eliminated strain

BEFORE AFTER COST: $176, 000 COST RECOVERY TIME: 6 -12 months BENEFITS: Eliminated strain from repetition and force, increased productivity and reduced manpower 2 0 8 0 2 0 0 0 6 0 4 0 Total Opinion Environment Vibration Head 6 0 Wrist Finger 4 0 Forearm Wrist 4 0 Elbow (side) Elbow (fwd) Back Twist Before After 15 Arm Finishing Dept. Sanding Position Force/Grip Movement 2 0 8 4 4 54 0 0

BEFORE Problem – manually scoop aluminum from furnace and 16 pour into mold

BEFORE Problem – manually scoop aluminum from furnace and 16 pour into mold

AFTER Solution -internally fabricated lift arms to suspend ladles allowing pourers to merely direct

AFTER Solution -internally fabricated lift arms to suspend ladles allowing pourers to merely direct movement of the arm 17

BEFORE AFTER COST: $5000 COST RECOVERY TIME: Three to six months. BENEFITS: Eliminated all

BEFORE AFTER COST: $5000 COST RECOVERY TIME: Three to six months. BENEFITS: Eliminated all shoulder and back injuries and burns. Reduced cycle times and fatigue which increased production. 8 2 4 0 0 0 Total Freq Grip Foot Opinion Deg Twisting 18 Frequency Position Perm Mold Hydraulic Weight Pourer Before 8 After 0 6 0 4 0 8 2 46 6 Grasp

BEFORE 19 Problem – two men needed to manually pour molds (40 lbs)

BEFORE 19 Problem – two men needed to manually pour molds (40 lbs)

AFTER Solution – automatic pouring machine 20

AFTER Solution – automatic pouring machine 20

BEFORE AFTER COST: $35, 000 COST RECOVERY TIME: Six months BENEFITS: Eliminated burns, shoulder

BEFORE AFTER COST: $35, 000 COST RECOVERY TIME: Six months BENEFITS: Eliminated burns, shoulder and back injuries, and manpower. Increased production. Before 8 8 4 0 6 4 8 8 46 After 21 0 0 0 0 0 Pourer Weight Position Total Grasp Opinion Frequency Twisting Hunter/ DISA Deg Freq Grip Foot

BEFORE 22 Problem – two men lift molding jacket sleeve (75 #) off mold

BEFORE 22 Problem – two men lift molding jacket sleeve (75 #) off mold after it was poured

AFTER Solution – one person uses a hydraulic lifting device 23

AFTER Solution – one person uses a hydraulic lifting device 23

AFTER BEFORE COST: $800 COST RECOVERY TIME: Two weeks BENEFITS: Elimination of back and

AFTER BEFORE COST: $800 COST RECOVERY TIME: Two weeks BENEFITS: Elimination of back and shoulder injuries, reduced manpower and increased productivity. Freq 2 2 0 0 Grip 2 0 Foot 4 0 Total 8 2 Deg 8 0 Grasp Opinion Before After 24 Weight 8 0 Frequency Twisting Removing jacket Position Big End/Osborn 6 2 38 6

BEFORE 25 Problem – Manually removing castings from shakeout and placing castings in a

BEFORE 25 Problem – Manually removing castings from shakeout and placing castings in a basket behind the worker

AFTER 26 Solution – robotic arm to grasp castings and put in basket

AFTER 26 Solution – robotic arm to grasp castings and put in basket

AFTER BEFORE COST: $25, 000 COST RECOVERY TIME: 8 -12 months BENEFITS: Eliminated strains

AFTER BEFORE COST: $25, 000 COST RECOVERY TIME: 8 -12 months BENEFITS: Eliminated strains from bending & lifting and burns, reduced silica exposure After 2 27 8 6 2 2 0 2 Grip Foot Total 8 Freq Opinion Before Deg Grasp Twisting Weight Frequency Position Shakeout 6 4 4 6 44 0 2 2 4 14

BEFORE Problem – used hand clamp to remove castings from die, great 28 deal

BEFORE Problem – used hand clamp to remove castings from die, great 28 deal of strain on shoulders and arms

AFTER 29 Solution – robotic arm to remove casting from die

AFTER 29 Solution – robotic arm to remove casting from die

BEFORE AFTER COST: $25, 000 COST RECOVERY TIME: 6 months BENEFITS: Eliminated strains from

BEFORE AFTER COST: $25, 000 COST RECOVERY TIME: 6 months BENEFITS: Eliminated strains from reaching & lifting. Reduced exposure to burns and increased productivity. 8 30 After 2 Freq 8 4 2 6 2 0 Grip Foot Total Before Deg Opinion Weight Grasp Twisting Remove Casting Frequency Position Perm Mold 0 4 8 8 42 0 2 2 2 16

BEFORE 31 Problem – manually attaching components to cooker with screw driver

BEFORE 31 Problem – manually attaching components to cooker with screw driver

AFTER Solution – pneumatic drivers 32

AFTER Solution – pneumatic drivers 32

AFTER BEFORE COST: $900 COST RECOVERY TIME: One week BENEFITS: Eliminated all wrist/shoulder strains.

AFTER BEFORE COST: $900 COST RECOVERY TIME: One week BENEFITS: Eliminated all wrist/shoulder strains. Productivity increased. 4 2 6 4 2 2 2 0 0 0 4 2 Total Opinion Environment Vibration Head 8 0 Wrist Finger 8 0 Forearm Wrist 2 2 Elbow (side) Elbow (fwd) Back Twist Before 33 After Arm Cooker Department Position Force/Grip Movement 2 2 0 0 4 44 0 0 0 14

BEFORE Problem – boxes were stapled on the bottom, flipped, and 34 stapled on

BEFORE Problem – boxes were stapled on the bottom, flipped, and 34 stapled on the top

AFTER Solution – tape machine tapes top and bottom 35 simultaneously

AFTER Solution – tape machine tapes top and bottom 35 simultaneously

AFTER BEFORE COST: $6, 000 COST RECOVERY TIME: One month BENEFITS: Eliminated all wrist/shoulder/back

AFTER BEFORE COST: $6, 000 COST RECOVERY TIME: One month BENEFITS: Eliminated all wrist/shoulder/back strains. Productivity increased. 4 0 2 0 4 0 8 0 4 0 2 0 Total Opinion Environment Vibration 4 0 Wrist Head 2 0 Forearm Finger 6 0 Elbow (side) Elbow (fwd) Back Wrist 36 Twist Before After Arm Cooker Department Position Force/Grip Movement 2 0 4 48 0 0

BEFORE Problem – pushing carts weighing 4, 500 lbs so that forklift 37 drivers

BEFORE Problem – pushing carts weighing 4, 500 lbs so that forklift 37 drivers could pick them up

AFTER Solution - put lights at the end of each workstation. The lights would

AFTER Solution - put lights at the end of each workstation. The lights would be turned on to signal the forklift drivers that a rack needed to be moved. Racks no longer moved manually 38

BEFORE AFTER Cost - $100 Cost recovery time – 2 weeks 39

BEFORE AFTER Cost - $100 Cost recovery time – 2 weeks 39