Case Studies Archive - ĢƵ /case-study/ Motion Control and Fluid Handling Solution Experts Mon, 18 Mar 2024 06:21:10 +0000 en-US hourly 1 https://wordpress.org/?v=7.0.2 /wp-content/uploads/2020/04/cropped-rg-favicon-2-32x32.png Case Studies Archive - ĢƵ /case-study/ 32 32 Compact HPU US Army /case-study/compact-hpu-us-army/ Wed, 05 Apr 2023 17:38:23 +0000 /?post_type=case-study&p=10213

Filling the void for a manufacturer of high-priority military apparatus

A combination of ĢƵ resources and products, resulted in an outcome that met specifications and saved lives

Customer/Industry
Manufacturer of Devices for the U.S. Military

Quantitative Snapshot
Helped military reduce catastrophic injury and mortality rate of U.S. Service Members from IED’s

How it began
A top manufacturer of military equipment and devices needed assistance developing hydraulic components that would support their proposed mine clearing solution.

How it evolved
The foundation for many of the ĢƵ projects start at the design stage. This organization worked with ĢƵ to create a hydraulic based solution to fit within the structure of equipment they currently had in development.

How it was resolved
ĢƵ was tasked with building and testing a hydraulic power unit that would be used for hydraulic actuation of a mine field clearing launcher.

Trusted Expertise, delivered
Within weeks, ĢƵ designed, fabricated and tested a complete system to fulfill their requirements. ĢƵ’s ability to provide seamless, homogenous support resulted in a complete drawing package, just-in-time delivery and creation of what would be the first of many units.

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]]> Live Entertainment Industry /case-study/live-entertainment-industry-engineered-solution-subassembly/ Wed, 05 Apr 2023 16:24:18 +0000 /?post_type=case-study&p=10206 Pneumatics and Creativity Paired for a Powerful Performance

ĢƵ manufacturing and assembly expertise enabled a seamless process to reduce costs, increase productivity and enhance ROI

Customer/Industry
Live entertainment industry

Components
Parker Origa Rodless Cylinders, Large H Series Directional Valves, Ace Shock Absorbers

Resources
Engineered Solutions
Sub Assembly

How it began

An entertainment company came to us for a solution to move “ice” spikes for their live production of Frozen Live Show at Disneyland.

How it evolved
ĢƵ’s engineering team began developing concepts that would not only be able to meet this objective, but would provide a safe, repeatable operation time after time. It was decided to formulate a custom solution using parker rodless air cylinders and deceleration units to accomplish this function.

How it was resolved
Having met the customers requirements and ĢƵ’s stringent testing procedures, the final design included an assembled custom rodless cylinder. Expectations were for it to travel 6 feet in fractions of a second. The final solution met this criteria, travelling 6 feet in .5 seconds.

Trusted Expertise, delivered
ĢƵ met the specification for the complete pneumatic solution by utilizing our expertise and world class pneumatic products. This solution is specified to operate two times daily for 10 years, with performances occurring every day.

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]]> FANUC Fenceless Palletizing Case Study /case-study/fanuc-fenceless-palletizing-case-study/ Thu, 08 Sep 2022 05:25:11 +0000 /?post_type=case-study&p=9810

Safety First – Increasing Worker Safety Through Automation

Over the past 30 years, there have been only 27 robot-related workplace deaths according to OSHA incident reports. That is a relatively low number compared to the 4,585 overall fatalities recorded by the U.S. Bureau of Labor Statistics during this time period. Of course, an ideal work environment wouldn’t have any accidents. While we haven’t quite reached this goal, automation seems to be a step in the right direction.

Ask an Expert

…and start working on your solution today.

The Customer’s Needs

Our customer came to us to help them resolve the issue of worker safety. They had a worker manually loading pallets coming off a continuous conveyor belt during a 24/7 work schedule. The person(s) would end up lifting boxes up to 30 lbs. for an eight-hour shift, leading to several types of possible injuries.

ʰ𳦳:Design, build and test an automated palletizing system

Our customer had an existing palletizing operation that required workers to continually lift and stack heavy boxes. They ran three shifts and were finding it impossible to find workers who were willing and able to perform that task for any length of time without associated stress or repeated motion injuries. The solution needed to fit within their existing footprint without sacrificing their safety protocols.

Result: ĢƵ designed and implemented an automated system utilizing the FANUC M710iC Dual-Sided Palletizer.

The robot is set up within a station that allows the operator to enter the work cell while the robot is palletizing. This is possible because of several critical safety protocols that have been put in place. The first is the area scanner and light current sensors. They manage both vertical and horizontal safe zones. If these zones are crossed in any way, the robot immediately stops.

The second is FANUC’s  Duel Check Safety, or DCS System. The DCS is a motion safety system that executes position checks as well as safe zone checks. These checks ensure operator safety within a blocked safe zone. This creates automatic robot movement restrictions which allows continuous operation.

ĢƵ Advantage: The system was designed to work a 24 hour shift with no downtime! It will handle several different size or shaped boxes and is easily configurable with a simple HDMI interface.

The end result is a system that satisfies the safety and labor concerns of the customer and has a fast ROI payback of only 18 months.

FANUC M-710iC Dual Sided Palletizing Automation Cell

The six-axis M-710iC/45M robot is a member of the family of M-710iC material handling robots with payload capabilities ranging from 12 kg to 70 kg. The robot provides high-speed operation, a 2606 mm reach and 45 kg payload. Its slim wrist, rigid arm, and compact size allows it to work well in tight spaces. The robot’s long reach and six-axis articulation make it a good choice for palletizing, packing, bin picking and other applications found in warehousing, logistics and e-commerce.

https://youtube.com/watch?v=PhmDc7ye8Us%3Ffeature%3Doembed

Conducting A Safety Assessment

Article written by: Mike Kunkle (MEK Consulting)
Industrial Robot Safety Consulting


Today’s manufacturing environment is demanding reduction of the robotic manufacturing footprint to conserve costly factory square footage, thus reducing operating overhead costs. As a result, we are seeing more and more fenceless robot installations.

Safety-rated soft axis and space limiting is an optional feature on today’s robots which is widely accredited with saving millions of square feet of manufacturing floor space. This feature, has the ability to set a safety-rated soft limit point, where a stop is initiated, or it might ensure that the robot does not move beyond a set limit.

Conducting a robot risk assessment in accordance with the ANSI/RIA R15.06-2012 Safety Requirements for Industrial Robots and Systems and the RIA TR R15.306-2016 Task-based Risk Assessment Methodology will assure risk to workers has been reduced to an acceptable level.

This palletizing system is employing Fanuc’s DSC which is their terminology for Safety-rated soft axis and space limiting. A limit has been set to ensure that the robot does not move beyond a set area. Four laser safety scanners have been integrated into this system to work in conjunction with DCS. These laser scanners keep unauthorized personnel from getting into harm’s way, but in conjunction with a request to enter gate box will allow the operator to safely remove a pallet of product from one system loading zone, while the robot can keep palletizing product in the other zone. The fence panels of the system were put into place in order to keep people taking factory tours from interfering and slowing down production. Their safety has already been considered and assured with the use of the safety laser scanners.

Let Us Help You.

Talk to one of our experts and start working on your solution today.

Interested in learning more about FANUC robots?

Contact Us

]]> Packaging and Container Manufacturer /case-study/packaging-and-container-manufacturer/ Tue, 06 Sep 2022 09:13:08 +0000 /?post_type=case-study&p=9600

Robotic Solutions Improve Productivity and Keep Workforce Issues at Bay

ĢƵ’s extensive IA and robotics products and technologies provide solutions beyond point of sale with short ROI

Customer/Industry
Packaging and Container
Manufacturer

Components
FANUC Robotic Custom
Palletizing Cell

Resources
Engineered Solutions,
Industrial Automation

Quantitative snapshot
8-month ROI

How it began
A global manufacturer of full line reusable totes, pallets, and custom size plastic products began experiencing reduction in product output due to labor shortages. To address this challenge, they began evaluating automated options for their tote palletizing work cell but had issues utilizing in house engineering resources.

How it evolved
Beyond its proficiency in robotics and industrial automation, ĢƵ provided a collect suite of assets like project management, integration and after sale support that this customer was looking for while searching for palletizing solutions.

How it was resolved
As a FANUC Certified System Integrator, ĢƵ developed a custom robotic cell that had the capabilities of assembling and palletizing the plastic totes. Solving multiple steps with one device.

Trusted Expertise, delivered
Monoflo was able to effectively stay ahead of the workforce decline and increase production throughput at their facility.

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]]> Food and Beverage /case-study/food-and-beverage/ Tue, 06 Sep 2022 09:09:11 +0000 /?post_type=case-study&p=9597

Automation Expertise Proves a Sound Recipe for this Food and Bev Company

With workforce issues disrupting production, ĢƵ implemented a solution that kept business in motion and paid off quickly

Customer/Industry
Food and Beverage

Components
PalletizHD, Doosan H2017

Resources
Engineered Solutions,
Industrial Automation

How it began
A national manufacturer of meatball products wanted to automate their manual palletizing processes utilizing a collaborative robot. When they originally considered this option, floor space in their facility prohibited if from becoming a reality. Additionally at the time, current offerings in the marketplace could not meet payload requirements.

How it evolved
With its vast experience, ĢƵ was brought in part because of its technological expertise in palletizing applications, integration and robotics. This along with its demonstrated past performance in the Food and Beverage industry made it a perfect fit for the project.

How it was resolved
With the PalletizHD and its unprecedented 25 kg Doosan collaborative robot, the ĢƵ developed and supplied a solution to satisfy Buona Vita’s special and payload needs.

Trusted Expertise, delivered
The culmination of this project allowed Buona Vita to continue meeting their production volume and customer demand while dealing with a volatile labor market.

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]]> Immunoassay and Clinical Chemistry Analyzer Manufacturer /case-study/immunoassay-and-clinical-chemistry-analyzer-manufacturer/ Tue, 06 Sep 2022 09:05:55 +0000 /?post_type=case-study&p=9594

A World of Solutions for Global Supply Chain and Product Management

ĢƵ developed a cost-saving solution to maximize efficiency and increase ROI

Customer/Industry
Immunoassay and Clinical
Chemistry Analyzer
Manufacturer

Components
Connectors, Couplings, Tubing

Resources
Vendor Managed Inventory;
Distribution Services

How it began
A leading biochemical testing manufacturer wanted to simplify their supply chain operations, relying on a single source to identify and manage their global supply of key components.

How it evolved
With over 65 years of manufacturing and distribution experience, the ĢƵ was brought in to assist the client team in formulating a product management solution. The goal, to compile a comprehensive list of CPC couplers, Air Logic regulators, and Saint-Gobain tubing used in the manufacturing of their devices.

How it was resolved
As a result of this initiative, ĢƵ developed processes that would allow the client to maximize discount schedules, consolidate purchase orders and lower the transaction cost per purchase order.

Trusted Expertise, delivered
The culmination of this project allowed the client to realize competitive market pricing for the full volume of business.

As a strategic partner, the ĢƵ has remained the global supplier and supply chain management partner of choice for the last ten years and counting.

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]]> Manufacturer of CPAP Machinery /case-study/manufacturer-of-cpap-machinery/ Tue, 06 Sep 2022 09:00:56 +0000 /?post_type=case-study&p=9591

Breathing New Life Into Solution Options for This CPAP Manufacturer

A combination of ĢƵ resources and products, resulted an outcome that met government specifications and yielded big consumer results

Customer/Industry
Manufacturer of CPAP
Machinery

Components
Oxygen Quick Connectors

Resources
Vendor and ĢƵ
Engineered Solutions

How it began
A top manufacturer of CPAP and Ventilator machines needed a convenient way to connect an oxygen inlet to their devices. After an internal review, they leaned towards a quick coupler rather than a barbed fitting, determining it would be better received in the home heath care space, as well as the hospital market.

How it evolved
The foundation for many of the ĢƵ projects start at the design stage. Having the engineering expertise and strategic vendor partners to provide unique fluid and gas connection solutions for this market, this manufacture confidently chose ĢƵ.

How it was resolved
The ĢƵ utilized fluid handling technologies to meet project requirements, developing a robust connector system for the machine side and a disposable, break-away connector for the insert side – at a cost-effective price point.

Trusted Expertise, delivered
As a result of this solution, the customer’s product was well received by the consumer market. Additionally, they were awarded a government BARDA contract to supply stock for equipment used during the pandemic.

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]]> Intra-Aortic Balloon (IABP) Counterpulsation Therapy /case-study/intra-aortic-balloon-iabp-counterpulsation-therapy/ Tue, 06 Sep 2022 08:57:33 +0000 /?post_type=case-study&p=9583

Putting It All Together in One Comprehensive Package

A turnkey solution that utilized a full-spectrum of ĢƵ capabilities, resulted in measurable results across all metrics

Customer/Industry
Intra-Aortic Balloon (IABP)
Counterpulsation Therapy

Resources
Engineered Solutions;
Contract Manufacturing;
Assembly; Distribution

How it began
Not having the expertise or logistical capability to handle all the intricate components a new project, a leading medical device company was looking for a turnkey solution.

How it evolved
With an extensive menu of manufacturing, vendor managed inventory and engineering capabilities, the ĢƵ was contracted to create a solution that encompassed all aspects of the project, including manufacturing, assembly, testing and shipping.

How it was resolved
The ĢƵ’s engineering team developed a test bench process to check for helium leaks at a pressure of 6,000 PSI, resulting in product integrity being 100%. Manufacturing, assembly, testing and shipping of the finished product used to deliver high pressure helium into therapeutic applications were all handled seamlessly by one source, the ĢƵ.

Trusted Expertise, delivered
Ensuring consistency and accuracy throughout each stage of the process was of paramount importance to this customer. The partnership with this client spans 10 years and still employs the supply chain,expertise that allows for the continued production of reliable assemblies for this critical market.

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]]> Ultrasonic Cleaning Equipment Manufacturer /case-study/ultrasonic-cleaning-equipment-manufacturer/ Tue, 06 Sep 2022 08:47:31 +0000 /?post_type=case-study&p=9567

Putting the Pieces Together with a Diversity of Assembly Options

ĢƵ manufacturing and assembly expertise enabled a seamless process to reduce costs, increase productivity and enhance ROI

Customer/Industry
Ultrasonic Cleaning
Equipment Manufacturer

Components
Tubing

Resources
Engineered Solutions;
Assembly/Sub Assembly
Services

How it began

A major device cleaning manufacturer was looking for a way to increase their tube assembly productivity.

How it evolved
Utilizing an extensive understanding of plastics production, ĢƵ was selected to analyze existing technologies then determine an action plan that would employ both production and assembly options.

How it was resolved
Upon reviewing the current size and methods of production, ĢƵ developed a solution that involved reducing the tube size at the extruding facility through an over mold manufacturing technique. This process simplified the production further, incorporating ĢƵ’s assembly capabilities by providing a fully assembled component.

Trusted Expertise, delivered
This ĢƵ solution enabled the customer to receive and install a finished product. This eliminated deficiencies, expedited assembly and fostered the production of a more robust product that was easier to manufacture.

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]]> Entertainment Industry OEM /case-study/entertainment-industry-oem-2/ Tue, 06 Sep 2022 08:25:17 +0000 /?post_type=case-study&p=9565 Opportunity: Design and build custom hydraulic system for braking control of large motion simulator.

Result: ĢƵ built and delivered a complete hydraulic system, including hydraulic cylinders, power units, proportional control manifolds and accumulators. The system solved the challenge of deceleration and braking of a large electric actuator. In an ironic twist, the original motion simulator design was hydraulic, then later was changed to a large electric actuator. During the design process, it was discovered that while the electric actuator had the capability to move and control the load, it did not have the capacity to decelerate and stop the load-hydraulics to the rescue!!

The ĢƵ Advantage: The ĢƵ Team was able to provide a completely assembled, fully integrated hydraulic system, pre-tested and ready for installation. We worked directly with our customer to solve the complex control scheme required to achieve the desired result-accurate dynamic control with safety and redundancy features.

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