Improving the Work Environment for Processing Equipment
CKD Corporation, Komaki Plant
Our plant has equipment that processes products.
Previously, one person would lift a workpiece of up to 21 kg to the input port of the processing machine, which posed dangers such as back pain from awkward postures, getting hands caught by the heavy workpiece, or dropping it.
Although we also used a crane for transport, it could not be installed near the work area, which created the hassle of moving it each time.In addition, the work required completion of crane operation training.
Challenges
Transporting 21 kg products, significant physical strain
In the product assembly process, one person traditionally had to lift a 21 kg product into a container, and then transport it from the container to the input port of the processing machine.
This process involved the following challenges:
・ Handling heavy objects places a great strain on The body, such as on The shoulders and back.
・ The work area layout is not well-organized, resulting In poor workflow and inefficient transport.
・ Work using a crane is limited to certain qualified operators.
・ Handling precision parts requires extreme care to avoid scratches, which also causes significant mental strain.
Since this is a mandatory task for product shipment, we considered improvement measures to reduce the burden on workers.
Reason for Adoption
An air balancer that can be installed even in a narrow space
As an improvement initiative, we first observed the actual work scene of a Flex Arm that had already been installed at another of our company's plants.
We determined that the Flex Arm would lead to a solution because it can be used even in narrow work areas, allowing installation without changing the current space or aisles, and because it is all-air, it can operate without electrical wiring.
In addition, its relatively affordable price also encouraged its adoption.
Post-Installation Effects
Reduced burden even for one-person work in a safe posture
By installing the Flex Arm, transport work can now be performed in a safe posture, significantly reducing the physical and mental burden on workers.
Taking this opportunity to review the site layout also reduced waste in transport and movement, which led not only to a reduced burden on workers but also to an improved environment for the entire site.
In the future, if an increase in payload or energy-saving effects can be expected, the consideration of electrification is also anticipated, and we will consider initiatives to realize even better products.