Case Study

    Handling Fixture

    Eliminating the bottleneck in manufacturing an oversized product

    Challenge: Inefficient Process & High Staffing Demands

    The client faced limitations in manufacturing finished products. The original method required high manual labor and showed these shortcomings:

    Low FlexibilityReconfiguring the process for different product dimensions was lengthy and inefficient.
    Capacity BindingHandling required excessive staffing, increasing direct costs.
    Quality RiskLack of a dedicated fixture led to surface damage risk just before shipment.

    Solution

    Engineering Approach to Handling

    We designed and manufactured a handling system that functions as a universal interface between the product and transport equipment.

    Key Engineering Elements

    • Modular DesignQuick reconfiguration for different size ranges using pin joints.
    • Safe-Touch InterfaceContact surfaces fitted with low-abrasion materials for absolute surface protection.
    • Stability OptimizationDesign ensures safe load center of gravity, key for OHS compliance.
    Handling Fixture

    Implementation

    Implementation & Integration

    In large-format part production, handling is often a hidden cost that slows production pace.

    Step 1

    Load Simulations

    Calculation and dimensioning of the structure considering safety factors.

    Step 2

    Production & Certification

    Precision engineering production with emphasis on rigidity and long service life.

    Step 3

    In-Service Validation

    Functionality verification when handling the largest available dimensions in client portfolio.

    Results

    Key Benefits

    Fixture implementation brought immediate production flow optimization.

    –60%

    reduction in handling staffing requirements

    Faster

    reduced handling cycle time and shipment preparation

    0%

    elimination of defect rate during transfer

    OHS ✓

    stable and predictable process meeting regulations

    Client Benefit

    Strategic Production Benefit

    For a medium-sized manufacturing company with its own R&D, this solution primarily means process standardization. Handling stopped being a critical bottleneck and became a predictable and safe step. Thanks to significant staffing savings, the client could more efficiently distribute labor to higher value-added areas.