Enhanced Ergonomics and Productivity for Aerospace and Defense

The aerospace and defense industries are rebounding after initial pandemic setbacks, leading to a surge in orders for top-notch engine and precision parts, structural components, and aeronautical subassemblies. With industry revenue surpassing $712 billion in 2021, operating profits have surged by 136%, according to PwC analysis. Additionally, global military spending reached a record $2.1 trillion in 2021, as reported by the Stockholm International Peace Research Institute.

This uptick necessitates readiness from manufacturers and CNC machining centers to meet the heightened demand.

According to Deloitte US's 2024 Aerospace and Defense Industry Outlook, new technologies are driving digital transformation and operational efficiencies. Deloitte emphasizes that aerospace and defense firms focusing on innovation and leveraging efficiency- and productivity-enhancing technologies, such as lift-assist solutions offered by 3arm America, will be better equipped for the challenges of 2024 & beyond.

Given the ever-evolving technological landscape in aerospace, high-quality CNC machining remains pivotal. Engineering teams at high-volume CNC machining centers are exploring new technologies to enhance production and quality amid a growing shortage of skilled labor.

The aerospace industry's exacting standards demand the implementation of innovative technologies to streamline processes. For instance, automated deburring and finishing solutions ensure consistent adherence to tight tolerances, while lift-assist solutions enhance employee safety and retention by handling heavy parts and tools.

Addressing Productivity Challenges in Aerospace and Defense Industry CNC Machining Centers

The aerospace industry faced significant workforce reductions during the pandemic, with U.S. companies letting go of 57,000 employees. While the industry is poised for a resurgence, smaller manufacturers continue to struggle with job vacancies, exacerbating the skilled labor shortage. Highly specialized CNC positions, requiring apprenticeships and years of training, are particularly difficult to fill.

To alleviate strain on valuable employees and enhance safety and retention efforts, machining centers must address understaffing issues. Overworked operators, often burdened with the constant lifting of heavy parts and tool holders, are at increased risk of injuries, accidents, and decreased productivity. The consequences can be costly, including damage to parts and tool holders, repetitive motion injuries, accidents, and reduced product quality.

In heavy production CNC centers, operators commonly handle dozens of heavy tool holders, some weighing up to 45 pounds, while setting up for new jobs. The process of affixing holders to the spindle, often in awkward positions, can lead to musculoskeletal disorders due to repetitive lifting and awkward positioning.

For instance, in aerospace manufacturing, operators may handle tool holders weighing 20 pounds or more, along with sharp milling cutters and carbide inserts. Inserting tool holders upside down into the spindle further increases the risk of accidents and injuries, requiring operators to contort their bodies.

Efforts to mitigate these challenges are crucial for maintaining productivity, ensuring employee well-being, and sustaining business success in the aerospace and defense industry.

The Adverse Impact of Workplace Injuries in Aerospace and Defense Industries

In the scenario described earlier, operators repeatedly handle approximately 45 pounds of weight when maneuvering in and out of the CNC machine, putting themselves at risk of cuts, muscle strains, and other injuries. According to the Bureau of Labor Statistics (BLS), over 50 percent of non-fatal occupational injuries resulting in missed work are attributed to musculoskeletal disorders, with the shoulders, back, hands, knees, and ankles being the most commonly affected areas.

Workplace injuries pose significant financial burdens to manufacturers. A single carpal tunnel claim, for instance, can incur nearly $65,000 in direct and indirect expenses, impacting various aspects such as:

? Diminished Safety: Operator fatigue can lead to lapses in attention regarding tool placement, potentially resulting in accidents, injuries, and damage to both expensive tools and the products being worked on.

? Long-Term Health Concerns: Repetitive motions, strain from lifting heavy weights, and awkward body positions required for tool attachment can contribute to operators developing physical injuries over time.

? Rising Expenses: Workplace injuries, damaged tools and products, inconsistent quality, and inefficient processes lead to increased costs, including higher scrap rates and production time.

? Employee Turnover: Workers exposed to safety hazards may retire prematurely or seek alternative employment, depriving the company of valuable industry expertise.

? Recruitment Challenges: Prospective employees consider the physical demands of the job, making companies offering ergonomic lift assistance devices like 3arm more attractive. This can also foster diversity within the talent pool.

? Team Morale: Jobs with health and safety risks negatively impact morale. Implementing solutions like 3arm demonstrates a commitment to employee well-being, fostering a positive work environment, boosting productivity, and enhancing job satisfaction.

Advantages of Implementing a 3arm Manipulator in Machining Centers

Investing in a lift assist solution like 3arm's M5 Manipulator can significantly mitigate the negative impacts associated with manual tasks. By effortlessly lifting and manipulating tooling for CNC machines, the M5 Manipulator reduces operator fatigue and strain. This versatile lift assist solution is capable of handling any type and size of CNC tool weighing up to 110 pounds.

The 3arm Manipulator effectively carries the weight of tools and tool holders, accurately orients and deposits tool holders into preset locations at machining centers, and facilitates the changing of end mills, drills, inserts, or deburring and finishing brushes. Once the offset is determined, operators can retrieve parts from the preset and safely return them to the spindle or magazine of the machine, eliminating the need for operators to exert unsafe levels of force during these tasks.

Designed as a "pick and place" solution, 3arm's Manipulator offers a wide range of mounting options and accessories to enhance ergonomics, reach, and mobility. Installing an M5 Manipulator on a custom-built trolley cart provides maximum versatility for machining centers, enabling operators to effortlessly move and position the arm as needed.

Key Features of the M5 Manipulator – the Premier Arm for Pick and Place Operations:

- Versatile Gripper Options: Choose from gripper jaws, vacuum, or magnet attachments to suit diverse handling needs.

- Customized Grippers: Ensures delicate parts are securely held without risk of damage during pick-up.

- Handle Variety: Various handle options are available for enhanced control and comfort.

- Optional Rotating and Revolving Head Assemblies: Provides additional flexibility in maneuvering.

- Impressive Reach: Offers a vertical reach of 28 inches and a horizontal reach of 65 inches.

- High Weight Capacity: Capable of lifting loads up to 110 pounds.

- Mounting Flexibility: Can be base- or top-mounted to accommodate different workspace configurations.

- Brake Options: Available with or without brakes for added stability and safety.

- Suited for Indoor Industrial Environments: Ideal for use in indoor industrial settings.

This example of a custom-built Manipulator arm and trolley underscores the advantages of implementing a 3arm lift assist solution for high-volume CNC machining centers.

The manipulator is mounted onto a vertical column affixed to a counterweighted trolley. This column provides adjustable vertical reach capabilities, extending up to 28 inches, while the counterweights ensure compatibility with tools of varying weights.

Equipped with a battery pack, the trolley powers its electric wheels and features a handle for controlling trolley movement and adjusting the arm's height on the column. Additionally, a small compressor housed within the trolley powers the pneumatic arm, which boasts a maximum horizontal reach of 65 inches.

The Manipulator's arm is designed with a handlebar for easy maneuverability, customizable head members for tool holder rotation, and interchangeable tool holders. Quick-change jaw grippers are provided for HSK, CAT 50, and other tool holders.

3arm's M5 Manipulator arm offers versatility and ease of use, making it an ideal solution for aerospace and defense industry CNC machining centers seeking to safeguard their most valuable assets: their employees. In today’s competitive labor market, attracting and retaining skilled personnel is paramount, and enhancing employee health and safety yields significant cost benefits.

Investing in a 3arm Manipulator for high-volume, high-precision work not only enhances productivity and work quality but also demonstrates a commitment to employee well-being. Contact Keystone today to explore how we can tailor a solution to meet your needs.