Case Studies

zeroG® arm systems have been successfully implemented by some of the world’s leading companies to boost productivity and reduce injuries. Whether holding tools or allowing workers to maneuver parts, zeroG® provides optimal fine motor control while greatly reducing fatigue that can cause injuries and errors. Below are some examples of zeroG® success stories.

AIRCRAFT OEM - Fixture Drilling

ROI 366% in payback of .27 years

Drilling Example

Equipois zeroG Solution:

zeroG is a proven solution for drilling that eliminates the weight of the tool, while still allowing use of the tool with complete range of motion.

Customer Benefits (ROI)

  • Verified injury data from this application, zeroG® 100% eliminated
  • Improved employee morale

Common Problem with Drilling in Aerospace Manufacturing:

  • Low repetition, but very awkward reach needed with heavy tool
  • Three different Quackenbush in-line drills used with different size bits (quick change req'd.)

Aircraft OEM Customer Specific Problem:

  • Manufacturing location for aircraft
  • Area considered is flap hinge on tail section

Aircraft OEM Solution:

  • Ring gimbal with removable inner race. Inner race stays with each tool
  • Special quick release outer ring allows for quick tool change

Acrobat Document zeroG Fixture Drilling Case Study and Specifications

AIRCRAFT OEM - Overhead Sanding

ROI 259% in payback of .43 years

Sanding Example

Equipois zeroG Solution:

zeroG is a proven solution for sanding that eliminates the weight of the tool, while still allowing use of the tool with complete range of motion.

Customer Benefits (ROI)

  • Reduced injury rate
  • Increase in productivity

Common Problem with Sanding in Aerospace Manufacturing:

Sanding is a standard process for aircraft painting and refurbishment. Typically, handheld palm sanders are used to allow navigation of tight spaces, but this process poses numerous risk factors: the large surface areas involved, the need to sand overhead, awkward arm positions, the long duration of the activity, and tool vibration. The result is high injury rates and reduced productivity.

Aircraft OEM Customer Specific Problem:

A major U.S. Airline has a large dedicated team that performs sanding in their aircraft refurbishment facilities. Traditionally, this area has been one of the most labor- intensive operations and an area with major production bottlenecks.

Aircraft OEM Solution:

zeroG® was installed to improve throughput while allowing the full range of movement needed to perform the task to the customer's stringent quality standards. zeroG® reduced the total hours required to sand
an aircraft by over 50%.

Acrobat Document Download Complete zeroG Overhead Sanding Case Study and Specifications


AIRCRAFT OEM - Compression Riveting

ROI 423% in payback of 4 months

Riveting Example

Equipois zeroG Solution:

zeroG is a proven solution for riveting that eliminates the weight of the tool, while still allowing use of the tool with complete range of motion.

Customer Benefits (ROI)

  • Injury avoidance
  • Reduced downtime due to exhaustion
  • Improved quality due to more precision in guidance of the tool

Common Problem with Riveting in Aerospace Manufacturing:

Heavy compression riveting tools is a typical requirement of most aerospace manufacturing. Many riveting tools are used overhead or in awkward postures that place stress on the user and compromise precision.

Aircraft OEM Customer Specific Problem:

Significant injury problems were associated with the use of 28lb Rivet Gun used overhead and held at shoulder level for applying rivet to fuselage. The work area included long sections of the fuselage and elevated areas, which placed stress on the user and also compromised precision.

Aircraft OEM Solution:

zeroG systems with gimbals and 2-axis mounts created a slide rail system

Acrobat Document Download Full Riveting Case Study and Specifications

Automotive Manufacturer - Overhead Fastening Tools

ROI Payback of 393% in 3 months

Automotive Overhead Fastening

     Customer Benefits (ROI)

  • zeroG reduced the injury rate to zero
  • Increased productivity
  • Improved quality
  • Reduction in absenteesim and increase in employee satisfaction
  • Reduces tool repair costs

Acrobat Document Download Overhead Fastening Case Study and Specifications

Heavy Equipment Manufacturer - Pistol Grip Fastening Tools

ROI 244% in payback of 4.9 months

Fastening Example

Customer Benefits (ROI)

  • Injury Costs. Primary benefits include the reduction of operator fatigue and strain injuries. Direct and indirect medical costs can easily exceed US$40,000 for a single typical shoulder injury.
  • Productivity. The reduction in exertion from eliminating the weight of the tool provides much more than an ergonomic benefit. Many users report labor reductions of up to 50% through the use of zeroG®.
  • Increase in quality through greater precision
  • Employee satisfaction
  • Reduction of tool damage

Acrobat Document Download Case Study Component Fastening with Right Angle and Pistol Grip Tools

Mercury Marine - Grinding

 

Grinding Example Video

Customer Industry/Description of Problem

  • Grinding and polishing of 34 lb. customer part
  • Most challenging operation outsourced due severity of ergonomic problems

Known Data Regarding the Application

  • Multiple propellers held up to grinder/polisher - part to tool
  • Freedom of motion is critical given that a good polish is more 'art than science'

Solutions Considered

  • Various solutions considered to try to 'hold' the part.
  • Final solution incorporated specialized gimbal to hold multiple configs.

Reasons for Final Solution Selection

  • Gave the operator the same freedom of motion as manual operation

Customer Benefits (ROI)

  • Verified injury data from this application, zeroG® will 100% eliminate
  • Improved employee morale

Watch Video zeroG® at work for Mercury Marine

Heavy Equipment Manufacturer - Torque Tool

Torque Tool Example

Torque Tool Example

Customer Industry/Description of Problem

  • Heavy equipment manufacturer
  • Mounting "stirrup" bracket underneath transmission with 4 4" long bolts

Known Data Regarding the Application

  • 26 pound Uryu inline pulse tool in vertical orientation

Solutions Considered

  • Single link arm with static link due to limited vertical travel required
  • Ring gimbal with special mounting brackets to grab the tool

Reasons for Final Solution Selection

  • Cost, static location and limited tool range of motion requirement

Customer Benefits (ROI)

  • Injury risk avoidance

Foundry - Component Grinding

583% ROI payback of 2 months

 

zeroG_Grinding

Bradken Kilburn, Western Australia:

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

 

Acrobat Document Download Complete zeroG Component Grinding Case Study and Specifications

Barge manufacturer - Fixture Drilling

50% reduction in labor hours required to complete each grinding operation

Drilling Example

Customer Industry/Description of Problem

  • Significant injury and throughput problems in surface preparation prior to painting

Task

  • Overhead grinding on bottom and horizontal surfaces of barge
  • Work done from a man-lift to reach surfaces

zeroG® Solution

  • Complete zeroG system mounted to man-lift basket with adjustable positioning system
  • Robust design for tough outdoor environment - plasma welding slag in vicinity

Customer Benefits (ROI)

  • Significant (+50%) improvement in number of hours required to complete each operation
  • Elimination of shoulder injuries (rough cost $80k per incident)