Find It – Fix It Challenge Flashback: 2012 Winner
Terex Aerial Work Platform’s Huron, SD plant took top honors with its Pedestal Weld Station.
Terex’s improvement focused on the posture and comfort of the worker responsible for the fabrication of a pedestal. To complete this task, the worker had to climb inside a shell and weld vertical gussets, and a top plate, while lying down. Each day seven pedestals are fabricated, each taking 10 minutes to complete. The worker performed this task more than 70 minutes a day and often complained of contact stress to the legs and the hot environment.
To improve the task, the company engineered a table to support the pedestal in an upright position. This allowed the worker to weld the components while sitting upright. This fix eliminated both the “Butts Up” posture and “Contact” stress, and improved cycle time by 20 minutes.