How a weightless monorail solution eliminated ergonomic risks in a warehouse with mobile shelving
Improving ergonomics and safety in logistics processes is one of the main challenges facing the industry today. In many warehouses, operators continue to perform manual handling tasks that, while they may seem manageable on occasion, generate significant physical strain when repeated throughout the workday.
At Téciman Ingeniería we have developed and implemented a solution for weightless assisted manipulation suspended on monorail to eliminate the ergonomic risks associated with handling coils in an industrial warehouse with significant space limitations.
The challenge: manual handling of coils and ergonomic risk
Our client was facing a situation common in many industrial environments: operators had to manually handle coils of approximately 25 kg of weight continuously during their workday.
This operation presented several problems:
- Accumulated physical fatigue.
- Increased risk of musculoskeletal injuries.
- Lower efficiency in storage and order preparation operations.
- The need to maintain productivity without compromising worker safety.
Furthermore, the warehouse presented an additional complexity due to the presence of mobile shelving and a very limited available height for the installation of new handling equipment.
Engineering analysis for a customized solution
Before defining the technical solution, our engineering team carried out a complete analysis of warehouse operationsstudying the routes of the operators, the collection and deposit points of the coils, the structural restrictions and the movements of the mobile shelving.
Following this study, it was determined that the best alternative was the implementation of a system of weightless, capable of lifting, moving, and positioning the coils with complete safety and minimal effort on the part of the operator.
The goal was to enable the worker to handle loads in a virtually weightless manner, eliminating overexertion and significantly improving the ergonomic conditions of the workstation.
Design of a monorail system adapted to the warehouse
To ensure access to all storage locations, a 17-meter-long monorail system fully adapted to the characteristics of the warehouse.
This system allows the weightless manipulator to move smoothly throughout the work area, facilitating the transport and positioning of the coils in any required location.
The solution was specially designed to integrate into an environment where every available centimeter was critical, maintaining the functionality of the mobile shelving and avoiding interference with normal operations.
- Watch a video of the system in operation: https://youtube.com/shorts/CxKx63OZAa4?feature=share
Optimization of available height through a specific structural solution
One of the biggest challenges of the project was the limited free height in the facility.
To resolve this situation, our engineers developed a specific structural solution based on a auxiliary beam and a custom-designed anchoring system.
Thanks to this configuration it was possible:
- Integrate the monorail within the available space.
- Avoid interference with mobile shelving.
- Maximize the useful working height.
- Ensure the stability and safety of the installation.
This approach made it possible to take full advantage of the existing infrastructure without the need for significant modifications to the warehouse.
Integrated safety between the weightless and the mobile shelving
Safety was another key aspect of the project.
To avoid potential risks during operation, our automation engineering team developed a security system which coordinates the operation of the weightless manipulator with the mobile shelving.
The system prevents the shelving from moving while the weightless device is not in its parking position, eliminating potential interference and ensuring a completely safe operation for both workers and the facility.
Benefits of the implemented weightless solution
The implementation of this system has yielded significant operational and ergonomic advantages:
- Elimination of the effort associated with the manual handling of coils.
- Reduction of the risk of injuries and work absences.
- Improving ergonomics in the workplace.
- Increased operational safety.
- Optimization of handling times.
- Perfect integration into a space with significant dimensional limitations.
- Greater comfort and productivity for operators.
Engineering applied to the improvement of industrial ergonomics
The incorporation of systems of weightless It has become one of the most effective solutions for improving ergonomics in industrial processes that require frequent handling of loads.
In Téciman Engineering We design customized solutions that combine mechanical engineering, automation, and industrial safety to adapt each project to the specific needs of our clients, guaranteeing safer, more efficient, and more productive work environments.
If your company needs to optimize load handling processes, reduce ergonomic risks, or integrate weightless systems in complex spaces, our team can help you develop the most suitable solution for your facility.
For more information, contact us by phone at 947 20 91 41 or by email at teciman@teciman.com. Follow us on LinkedIn to find out all the news.