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Creative, Low-Cost Solutions
Dan MacLeod
www.danmacleod.com
February 2, 2004
1. A Block of Wood
Before: Reaching out and holding a heavy metal
product while cranking in the fixture to hold it in place.
After: A two-by-four block saved the cost of an expensive loader
For a manufacturer of metal products, a priority problem was back injuries
from loading and unloading metal castings from a cut-off saw. Prior to
my
involvement, plant engineering was considering developing a hydraulic shuttle to
facilitate loading, with an estimated cost of about $8,000.00. After brainstorming with an
engineer and the operator of the saw for about 45 minutes, we concluded that a
small block of wood would solve the problem. There was a two-by-four in the area, the
employee had a wood saw in his car, and the improvement was implemented instantaneously.
Cost $0.00.
A later refinement involved adding a door hinge to the block.
Cost: $0.86.
2. A Length of Chain
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| Before: Holding heavy chuck with one
hand |
After: A chain supports the load |
At a high precision machine shop, an NC lathe operator had experienced shoulder
problems from changing chucks, and ultimately needed surgery. The operator was requesting
a hoist, as was used in other, nearby larger machines. However, congestion in the area
precluded this option. In conjunction with the operator, Dan brainstormed ideas that led
to the use of a chain hung from the lathe splash door track to support the chucks. Total
time from the start of the evaluation to the installation of the chain was two hours,
including the time it took the machine shop to tap several screw holes.
Cost: ~$20.00.
3. Duct Tape and PVC Pipe
For a manufacturer of medical devices, a problematic task was separating specially-coated wires. A hand wire-stripper had been tried
in the past, but the repetitive hand motions and high grasping forces involved from the
wire-stripper quickly led to its rejection. After reviewing and trying the task,
I went
to a nearby hardware store, purchased an assortment of items, then built a rudimentary
contraption that successfully accomplished the task.
Cost $28.43
(including full roll
of duct tape).
4. A Webbed Strap
For a metalworking operation as part of an overall survey of lower back stress and
other types of cumulative disorders, Dan was asked to evaluate a rotary draw bender. The
concern was high upper body exertions and loads on the lower back. The company was aware
of a $15,000 device that would eliminate these problems, and was in part requesting
support in helping justify this purchase. After some discussion and brainstorming, Dan
suggested adding a simple strap to hold the metal product in place. A suitable strap
happened to be hanging nearby, which was tried, solving the problem.
Cost: $0.00.
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