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Case StudyBradken Kilburn, Western Australia
zeroG® for Component Grinding & Metal Finishing
PROJECT ROI SUMMARY
TOTAL COST SAVINGS $219,720
Less Depreciation - $ 9,000
Less Annual Maintenance - $ 750
Total Net Savings $209,970 ________
TOTAL zeroG® ACQUISITION COST $ 36,000
ROI 583%Payback Period 0.17 years
The Bradken foundry in Kilburn, Western Australia had 14 injuries attributed to grinding over a 24 month period, four of which resulted in employees being placed on restricted duties. zeroG® reduced injury rates to zero. zeroG® reduced the total hours required for grinding related tasks by over 60%. Trip hazards were also reduced by running power leads through the zeroG® structure. Absenteeism in the grinding area was immediately reduced by nearly 50% due to improvement of worker safety and morale.
The use of heavy hand-held grinders is a typical requirement of casting, forging and metal fabrication. It is demanding and tiring work, which places considerable stress on the user. As a result, grinding is often considered to be one of the least desirable assignments and faces low retention and high absenteeism. The zeroG® from Equipois o�ers a proven solution for component grinding that both reduces injuries and boosts productivity. The patented system lets the operator maneuver the grinder as if weightless while preserving the complete freedom of motion required for the job. zeroG® grinding systems provide considerable costs savings and a compelling ROI for many of the largest manufacturing companies in the world. Satis�ed customers include Caterpillar, John Deere, Boeing, Ford and Toyota. As a result of their success, many zeroG® customers have gone on to implement the technology as a best practice.
Return-on-InvestmentInjury Costs — zeroG® grinding systems reduce operator fatigue and the potential for injury. For a typical shoulder injury, direct medical costs can exceed US$20,000. Indirect costs associated with lost time, retraining, etc., can be a multiple of direct costs, with total injury costs reaching US$80,000 or above for a single injury.
“It feels great…no vibrations or heavy arms any more…I feel the di�erence when I get home after a shift.”
– BRADKEN OPERATOR
Contact Equipois Inc. at (866) 601-2070
Equipois Inc.5440 McConnell AvenueLos Angeles, CA 90066
© Copyright 2011 Equipois Inc. All Rights Reserved. All trademarks are the property of their respective owners. Reference herein does not constitute or imply a�liation with, endorsement, or recommendation of Equipois Inc. products by the respective trademark owners.
zeroG® for Overhead Sanding
Contact Equipois Inc. at (310) 736-4130
zeroG® SolutionzeroG® Arm: zeroG4 Double Link Arm suitable for payloads 8 lbs to 36 lbs (2.72 kg to 16.33 kg) - Part Number 101-5000-21
- Heavy Duty Silicone Double Link Arm Cover – Part Number 300-2200
Gimbal and Post System: S1 Ring Gimbal with Post suitable for approved grinders – Part Number 400-8260-01, -02 or -03
- Docking Kit for securing the tool and arm when not in use – Part Number 400-6200-02
Mounting Solutions: Both �xed and portable mounting solutions are available:
- Fixed Mount 2-Axis Pre-Set Interface Mounting Block – Part Number 500-4200
- Fixed mount Heavy Duty Jib with 80/20 post to mount zeroG System to post or wall – Part Number 500-5630-72
- Portable Gantry System with top mounted linear rail –Part Numbers 500-5420-72, -96 or -144 (72, 96 or 144 inch rail)
- Portable zeroG4 Quad Stand – Part Number 500-5520
Return-on-Investment (continued)Productivity Enhancement — Many users report labor reductions of up to 50%. With zeroG®, operators can use more powerful grinders, further increasing productivity.
Tool Damage and Grinding Disc Usage — It is common to damage cords and hoses of grinders during usage. With zeroG® cables and hoses are festooned along the length of the arm to prevent damage. Also since tools are no longer dropped when not in use, tool repair costs are reduced. Finally, since tools can be held in an optimum position, grinding disc usage can be reduced, often by 30-40%, since more of the pad can be used and with proper pressure. Combining these e�ects, customers can see costs savings of US$500 to US$1,000 per year or more.
Quality — In many grinding applications the degree of precision can be made challenging by the use of a heavy tool. zeroG® allows worker to utilize their �ne motor skills to be more precise. Accordingly, use of the zeroG® arm can help improve the quality of processes where it is utilized. A reduction in the number of rejected parts is a common occurrence with zeroG® systems.
Employee Satisfaction — Grinding is often a task with low employee retention and high absenteeism. Many customers using zeroG® systems have seen almost immediate reductions in absenteeism (better than 50% in some cases) while also being able to return restricted duty employees to work by using zeroG®.
zeroG® for Component Grinding & Metal Finishing
Equipois Inc. 5440 McConnell Avenue, Los Angeles, CA [email protected] | www.equipoisinc.com
Speci�cations• Provides the full dynamic range of motion necessary for effective grinding.
• Zero power consumption - no electrical, pneumatic, or hydraulic power
source is required.
• Supports grinding tools weighing between 8 lbs. (3.63 kg) and 36 lbs. (16.33 kg).
• Supported grinding tools include standard right angle grinders, in-line grinders and vertical grinders. (See Approved Tools List for a complete listing of supported tools.)
• The fixed pre-set mount lift assist system will provide a working range of at least 58.63 inches (1489mm) from the mount.
• Utilizing the Heavy Jib reach extension, the working range for the system will be a radius of at least 141 inches (3581mm). The system will allow grinding of components as long as 240 inches (6096mm).
• The Portable Gantry mounting option provides a top mount linear rail to allow the grinding system to be mounted above or alongside the work area. Linear rails come in standard lengths of 72 inches (1829mm); 96 inches (2438mm); and 144 inches (3658mm).
• The zeroG4 Quad Stand portable cart mounting option provides a completely mobile, small-footprint cart to move the grinding system to almost any location.
• Reach and range of motion beyond the above limits may be feasible as a non-standard con�guration. Please contact Equipois for more information.
• Cabling such as pneumatic air lines, power cords, hydraulic hose or sensor wiring can be routed along the length of the system.
• Must be mounted to a structure that can support the full system and payload. Maximum moment load considerations for the structural design can be found on the system installation drawing.
• Includes protective covers, which will prevent grinding sparks and othercorrosive elements from damaging the zeroG arm while also protecting the user from pinch points.
Approved Tools ListGrinding Tools from the following manufacturers:
PRE-SET MOUNTING
INTERFACE BLOCK
NO. 500-4200
PIVOT
zeroG 4
DOUBLE LINK ARM
NO. 101-500-0XX
GRINDING TOOL
S1 RING GIMBAL & POST
SYSTEM NO. 400-8260-XX
(AVAILABLE IN 3 SIZES)
• Fein Power Tools
• Bosch Tools
• DeWalt
• Honsa Tools
• Milwaukee Tool
• Ingersoll-Rand
• Cleco (Cooper)
