Our employees should be relieved of physical strain. The new solution should be easy to use and at the same time enable a strain-free way of working.∼ Julian Wiegand, Team Leader Production Medical Sunrise GmbH
Sunrise Medical optimizes processes with vacuum lifters from Schmalz
Sunrise Medical, a leading global manufacturer of mobility aids, was repeatedly faced with a challenge: lifting heavy wheelchairs and batteries put a lot of strain on its employees. To ensure physical relief and improve working conditions, the company opted for innovative vacuum tube lifters from Schmalz. The result: significantly better ergonomics and fewer absences due to illness.
Characteristics of the success story
| Industry | Universal |
|---|---|
| Workpiece | Wheelchairs |
| Product group | Vacuum Tube Lifter JumboFlex |
| Type of handling | Manual Handling |
With Schmalz
2,000
kilogram
pain-free lifting
The Customer: Sunrise Medical GmbH
Sunrise Medical GmbH, headquartered in Malsch, Germany, is a global leader in the development, manufacture and distribution of innovative products for assisted mobility. These include manual and electrical wheelchairs, electric assistive drives, electric mobility scooters, seating and positioning systems as well as everyday aids and therapeutic aids for children and adults. With over 3,000 employees worldwide, Sunrise Medical is committed to improving the quality of life of people with physical disabilities.
The Challenge
Before the Schmalz solution was implemented, handling wheelchairs and their rechargeable batteries in the assembly and packaging areas at Sunrise Medical was a physically demanding task. Employees had to struggle to lift and transport the heavy and bulky items by hand. This often required up to two people. The rechargeable batteries weigh 10 kilograms and measure 31 x 22 x 29 centimeters, while the wheelchairs weigh 40 kilograms and measure 95 x 35 x 80 cm. Experience has shown that an employee moves between 30 and 50 items per shift, which means that the total load on a working day can add up to as much as 2,000 kilograms! This high physical strain was also associated with the risk of musculoskeletal disorders, which resulted in one to two sick days per quarter. Sunrise Medical looked for ways to significantly improve the ergonomics of the workplace in order to reduce the physical strain on employees and maintain their performance in the long term. At the same time, the aim was to reduce sickness-related absences due to musculoskeletal disorders. Team leader Julian Wiegand says: “Until now, batteries and wheelchairs had to be lifted into boxes by hand, which was a physically demanding process for employees. We wanted the new solution to be easy to use and at the same time enable a ergonomic working method that is easy on the body.”
Schmalz's Solution
To make handling more ergonomic and efficient, Sunrise Medical has opted for the JumboFlex 35, JumboFlex 50 and JumboFlex High-Stack vacuum tube lifters. The solution is complemented by a versatile overhead crane system and a smooth-running column-mounted jib crane. The tube lifters from the JumboFlex series enable ergonomic handling of light goods at high cycle rates. The comfortable control handle allows for long, fatigue-free working. With just two buttons, loads can be intuitively lifted, lowered, released, or held at any height. The JumboFlex 35 mounted on a column-mounted slewing crane is used for packing battery packs. The batteries are picked up and placed in shipping cartons using a suspension hook as a gripper. The cartons are then loaded onto transport trolleys. For wheelchair assembly, Sunrise Medical uses two vacuum lifters on a shared overhead crane system: First, the wheelchairs are lifted onto an assembly rack with the JumboFlex 50. After assembly, they are placed in shipping cartons, which are then stacked on pallets with the JumboFlex High-Stack. The High-Stack lives up to its name: cartons can be stacked effortlessly to a height of 2.55 meters without any physical strain. Maximum flexibility is ensured by an adjustable four head suction gripper that can be adapted to different carton sizes without the need for additional tools. Julian Wiegand, team leader at Sunrise Medical, draws a positive conclusion: "The employees are very satisfied. The operation is intuitive and enables work that is easy on the body. What's more, I can now distribute tasks to employees regardless of their physical condition: It's no longer the person lifting the wheelchair, but the vacuum lifter." Wiegand is also confident about the future: "We like the fact that the solution can be retrofitted or converted at any time. The collaboration with Schmalz was smooth and goal-oriented right from the start – we would choose them again at any time."
The multi-gripper for different carton sizes makes gripper changes superfluous
Previously done by hand and in pairs, now effortlessly with one person: the wheelchairs are placed in cardboard boxes after mounting
Effortless stacking up to a height of 2.55 meters with the JumboFlex High-Stack
The matching, particularly responsive cranes complete the system.
Customer benefits through the Schmalz solution
ErgonomicsPhysical relief for employees through the use of vacuum lifters
HealthReduction in sick leave due to musculoskeletal disorders
EfficiencyFaster order processing thanks to optimized handling processes
FlexibilityEasy retrofitting and conversion. Quick adaptation to different weights and dimensions of the products
Products used in the application
Vacuum Tube Lifters JumboFlex
- JumboFlex for ergonomic one-hand operation for fast movement sequences
- Configurable lifting unit, operator handle, vacuum gripper and vacuum generator
- Intuitive two-button control for up/down control, also available with proven one-button control on request
- For workpieces up to 50 kg
Vacuum Tube Lifters JumboFlex High-Stack
- JumboFlex High-Stack for back-friendly lifting and lowering of loads
- For optimal use of space in storage areas and transport equipment
- Up to a stacking height of 255 cm
- For workpieces up to 50 kg
Aluminum Bridge Cranes
- Modular crane system for flexible and cost-effective assembly of individual crane solutions
- Installation on ceiling or portal construction
- Particularly suitable for large workspaces
- Lift capacity up to 1,200 kg