Humantech Inc. recently named Terex Utilities, a division of Terex Aerial Work Platforms as the winner of its sixth annual Find It – Fix It Challenge. The Find It – Fix It Challenge recognizes and rewards simple and effective workplace solutions that increase productivity, improve worker morale and reduce workplace injuries and illnesses. The contest was derived from Humantech's RAPID Team Events, which are based on the concept of making quick, simple, visible changes to improve ergonomic issues in the workplace. Terex Utilities was selected from more than 150 entries, representing 24 companies.
Terex Utilities in Huron, S.D., took top honors with its Pedestal Weld Station entry. The improvement focused on improving the posture and comfort of the worker responsible for welding a vertical gusset and top plate to the metal shell of a pedestal. The pedestal connects a boom to a truck chassis and also houses the bearing that enables the boom to rotate while in operation. From digger derrick units used to set power poles to aerial devices with working heights of 125 feet, Terex fabricates large to small pedestals for its full line of utility equipment.
Prior to improving the task at the pedestal weld station, the worker had to climb in and out of a metal shell up to eight times per unit. While lying in a horizontal position, with legs dangling outside the pedestal, the worker had to weld parts of the pedestal together. When one section was complete, the welder would get out of the pedestal, rotate the pedestal to the next weld position, climb back into the unit, and weld the next section. Due to high air temperatures inside the pedestal, the welder had to lie on blankets for extra protection in addition to wearing welding leathers. A total of eight pedestals were fabricated each day using this process.
“We had strong internal support from the entire team,” said Bethany Kovash, Industrial Engineer. “This was a good example of designing for safety and manufacturability.”
With a $300 budget, the team engineered and fabricated a steel welding table to hold the pedestal in a vertical position. The team member can now perform the work in a seated position, eliminating what Humantech calls “Butts Up” postures and contact stress. The cycle time was also reduced by 20 minutes. In addition, the design engineering department redesigned the pedestal to eliminate the vertical gusset weld to a plug weld on the outside of the pedestal.
