Introduction
The Dagenham Engine Plant, a key manufacturing hub for Ford Motor Co., experienced a rapid increase in production volume. While a boon for business, this increase required more plant operators and significantly amplified the risk of common workplace injuries related to the manual handling of heavy aluminium cast and machined engine parts. This required a fast, scalable solution to ensure operator safety and sustain the demanding production pace.
Problem
The core challenge was the manual handling aspect of the workflow. Operators were required to frequently lift and twist their bodies to retrieve engine parts from large containers and load them onto the production line. As the containers emptied, the parts were lower, forcing operators to bend and stretch, greatly increasing the risk of musculoskeletal injuries, subsequent absenteeism, and potential liability issues.
Solution
The solution involved a comprehensive, plant-wide ergonomic upgrade where Edmolift provided and fitted Model TL2000 scissor lift platforms at all 200 workstations. This was not a standard installation, as the platforms were implemented with specific ergonomic features. As the stack of parts on the pallet decreases, the lift platform is slowly ‘inched’ higher, consistently maintaining the correct, ergonomic working height regardless of the operator’s stature or the current load level. Additionally, each lift incorporated a slew ring turntable, allowing the operator to easily rotate the pallet container, which eliminated stretching and reaching to access parts on the far side of the load.
Results
The implementation of these ergonomic scissor lifts had an immediate and measurable impact on operational health and efficiency. Greatly improved ergonomics across all 200 workstations directly led to a measurable reduction in employee sick days. Fewer injuries and a more comfortable working position resulted in greater overall productivity and profitability for the plant. Ultimately, Ford’s complete satisfaction with the results led them to immediately purchase a further 200 units to be rolled out at their other manufacturing plants across the UK.