Custom Machines Improve Safety While Still Boosting Efficiency

When manufacturers first approach us about a custom machine, efficiency and throughput are often the first things on their minds. Those goals are important, but we make it clear that improvements in safety and ergonomics can directly support productivity gains, as well. Learn why safety is a core consideration in every machine we design at Gemini Industrial.

Designing Safety in From the Start

Even if safety isn’t a customer’s main priority, we always emphasize that it’s essential to any successful machine. Safety is one of our core values at Gemini, both in how we operate and in the products we create; we aren’t willing to put our name on a machine that isn’t optimized for safety.

From the start, we integrate safety features like guarding, interlocks, and controls into the machine’s functionality. Our engineers work with customers to understand their workflow and operations. Then, we develop a solution to create efficient processes while protecting team members.

Sometimes, there can be tradeoffs that have to be negotiated in the engineering and design stage. Safety features, after all, cannot take away from the effectiveness and functionality of a machine. The right design depends on the customer’s process and priorities. 

Reducing Manual Handling and Ergonomic Risk

One customer for our machine building services, for example, had a process involving a heavy box that had to be flipped during production. The existing procedure required two employees because a single operator could not flip it safely. Each time the box needed to be turned, a second employee had to stop their own work to help.

We designed a box-flipping machine that was able to complete the process without manual lifting. The solution was, in part, a more efficient use of labor, but it also created a far safer process. The ergonomic risks from repeated lifting of heavy boxes were eliminated, in particular the potential for back injuries. The manufacturer was able to put their employees at ease and allow them to remain focused on their other work.

Improving Guarding Without Slowing Production

We have also helped manufacturers with solutions for existing equipment with exposed moving components, like blades or large rotating spools. In these situations, guarding is essential, but poorly designed guarding can create new problems if it affects functionality. Making material handling or changeover difficult, for instance, can undermine the usefulness of the machine.

For one winding application we helped with, large rotating spools required protective cages and safety interlocks. However, employees still needed quick access to change the spools and keep production moving. Our solution included a rapid-lift door that could move out of the way for changeovers while preventing the machine from operating when the guarded area was open. This type of design protects operators without making the machine impractical.

Safety and Productivity Support Each Other

Safety and productivity can effectively coexist in the same custom machine; in fact, safety can make your team more productive. Teams work more confidently and productively when they’re at ease around your equipment and not worried about potential hazards. 

A safer and more ergonomic process can reduce fatigue and prevent injuries and the disruptions that risk creates. By eliminating these concerns from the operator’s job, a well-designed custom machine ensures you can maintain a consistent workflow.

Let’s Discuss Ergonomics, Safety, and More

Custom machines can help with a variety of tasks, from improving ergonomics to eliminating exposure to dangers. If a process in your facility is creating safety concerns, a custom machine could be the solution. Contact us to discuss how our expert engineering team can improve both safety and efficiency in your operation!