Before the 2015 Challenge comes to a close, let’s remember the 2011 winner.
Timken’s Manchester, CT plant earned the winning trophy with its Bull Gear Deburring entry.
Their improvement focused on improving the posture and comfort of the worker responsible for deburring an 856 pound bull gear. Prior to the fix, the worker manually deburred the gear twice. (Deburring is the finishing method used to remove raised particles and metal shavings brought on by the processes required to create specific metal shapes, sizes, or indentations in metal; sanding, using abrasive cloths, or using a machine or grinder to smooth away nicks and fragments are some of the methods used). The first operation included deburring all 340 teeth, which included both sides of the gear teeth, and several key surfaces. The second operation deburrs all the gear teeth again, along with an additional 92 holes and 59 scalloped flanges.
For several hours, the worker had to stand and bend over the gear, in order to reach the gear teeth. When the first side was complete, the gear was flipped 180-degrees to deburr the other side.
The company engineered a solution to position it in a vertical/upright position, which made both sides accessible. Now, the worker is able to sit and perform the operation without bending. This improvement reduced the risk of injury from handling the gear, decreased the deburring time, improved the comfort of the worker, and reduced the stresses placed on the neck, back, shoulders and elbows.
To participate in this year’s Challenge, submit your entry today. Visit our website to learn how.