Enhancing Assembly Line Productivity with Additional Cranes in a Space-Constrained Environment

Industry:
Heavy Equipment Manufacturing

About the Customer:
A prominent manufacturer in the heavy equipment industry, this company aimed to expand its existing assembly line to increase productivity. The facility’s current setup included a 5-ton Single Girder Electric Overhead Traveling (SGEOT) crane operating on a ceiling-mounted structure, with limited capacity for additional lifting equipment.

The Challenge:
To meet production goals, the customer needed to expand the assembly line by adding three cranes, which required:

  • Space Optimization: Adding a 2-ton crane to an existing 10-meter bay initially designed to support only a 5-ton crane.
  • Extension of Assembly Line: Adding a 10-meter extension with two new 2-ton cranes and the necessary supporting structure.
  • Strict Timeline: Completing the project within a 20-day lead time to minimize disruptions and quickly realize productivity gains.

The Solution:
Sparkline provided a customized solution that maximized the utility of the existing infrastructure while meeting the tight deadline. Key components of the solution included:

  1. Addition of a 2-Ton Crane in the Existing Bay: Sparkline installed a 2-ton SGEOT crane within the existing 10-meter bay. To ensure compatibility and safety, the existing 5-ton hoist was de-rated to a 3-ton capacity, allowing both cranes to operate efficiently without overloading the bay’s structural support.
  2. Assembly Line Extension with New Cranes: Sparkline extended the assembly line by an additional 10 meters, installing two new 2-ton SGEOT cranes with a column-mounted structure. The design team accounted for the facility’s existing parameters and site conditions to ensure stability and seamless integration with the current setup.
  3. Rapid Project Completion: The project was completed within the 20-day timeframe, as committed, allowing the customer to maintain productivity without extended interruptions.

A Statement of Overall Benefit:
Sparkline’s solution enabled the customer to increase assembly line capacity efficiently, without extensive structural modifications. The quick turnaround provided the additional lifting capacity needed to support increased production demand with minimal capital expenditure.

Benefits:

  • Increased Productivity: The additional cranes enhanced assembly line throughput, enabling the facility to meet higher production targets.
  • Cost-Effective Expansion: By de-rating the existing hoist and utilizing the current bay structure, Sparkline minimized capital expenditure and reduced the need for extensive structural upgrades.
  • Timely Completion: Sparkline delivered the project within 20 days, minimizing downtime and allowing the customer to realize productivity benefits promptly.

Sparkline’s tailored approach provided an efficient, cost-effective solution that met the customer’s needs for increased capacity within a compact, existing assembly line environment.