Reducing Workload and Improving Efficiency of Gear Transport Operations Through the Introduction
of the Flex Arm
Itoh Gear Manufacturing Co., Ltd.
Itoh Gear Manufacturing Co., Ltd. is a company based in Kishiwada City, Osaka Prefecture, specializing in the cutting and processing of gears and related parts. Since its founding in 1951, the company has maintained integrated production from material procurement, manufacturing a wide variety of gears in small volumes to meet diverse needs. This case study introduces how CKD's assist device, the "Flex Arm," was used to reduce the burden of transporting heavy gears to inspection tables and pallets, achieving more efficient and safer operations.
Challenges
Challenges in reducing worker strain and improving efficiency in gear transport operations involving loads of up to 50 kg
The following issues were encountered when transporting gears as workpieces.
・Heavy burden on workers
With two workers transporting gears many times a day, the physical burden was significant. It was also necessary to find an available worker each time.
・Decreased work efficiency
Heavy workpieces could not be brought into the inspection room and had to be measured in areas without temperature control. This required using a crane to transport workpieces outside the inspection room and performing additional work to stabilize the temperature.This was labor-intensive and limited the available workers.
Additionally, the wide-ranging transport from pallets to four work tables and the CMM was a burden.
・Risk of workpiece damage
Dropping precision-machined workpieces could damage the workpieces themselves or surrounding equipment. The extreme care required also placed a significant mental burden on workers.
Reason for Adoption
Wide range of motion, flexible operation even in limited spaces
While considering auxiliary devices for workpiece transport, the customer was introduced to the Flex Arm through a distributor and expressed interest.
With a total height of just 2.5 m, the unit can be easily installed even in low-ceiling work areas, making it well suited for the space-constrained inspection room. The customer also appreciated the flexibility afforded by its wide range of motion, with a turning radius of 2.5 m and a vertical stroke of 1.5 m.
Effects After Introduction
Contributing to reduced worker strain and improved efficiency
The following results were observed after introducing the Flex Arm.
・Reduced workload
The arm supports the weight of the workpiece, reducing physical strain on the workers' lower back and shoulders.
・Repetitive tasks become easier
In addition, transport tasks that previously required two workers can now be handled by one, contributing to labor savings.
・Improved work efficiency
No special qualifications are required, so anyone can operate the unit - enabling the transport of heavy workpieces within the inspection room. Work efficiency is improved regardless of location or operator.
・Reduced risk of workpiece damage
Gentle raising and lowering enables transport without damaging workpieces or surrounding equipment. The mental burden on workers is also reduced.