Case Study: HYTORC Made Heavy Lifting Feel Weightless For a Car Manufacturer
HYTORC worked with a popular Japanese car company that’s famous for building some of the most reliable cars on the road. But behind every great car is a factory floor that runs on strict rules and smart solutions. In two of their factories, the customers faced a challenge of how to use powerful industrial tools while keeping their workers safe and comfortable.
Here is how they teamed up with HYTORC to solve a heavy problem with a "weightless" solution.
Challenge: The 2 Kilogram Rule
At this car company, safety wasn't just a suggestion, it's a rule. On the factory floor, there is a strict requirement that tools used by certain personnel must weigh no more than 2kg.
This created a puzzle for the manufacturing team. Engine block casting required heavy-duty bolting systems to get the job done right. Most industrial tools that were powerful enough for this work usually weighed much more than 2kg.
The LST and LION GUN allowed the customer to shorten the time of engine block cleaning maintenance. Also, they were able to utilize their S&W work campaign implementing Seniors and Women on the factory floor. – Paul Ossing, Growth manager, HYTORC Japan
Solution: The HYTORC LST
To meet their goals, the auto manufacturer started using HYTORC’s Lithium Series II electric torque tool. However, to stay under that 2kg limit, they decided to use a spring balancer instead of just handing the tool to the worker.
- The Pulley System: They attached the LST tool to a yellow pulley system known as a spring balancer. This system supported the weight of the tool, making it feel almost weightless to the person using it.
- Safety First: This allows the team to use the power of the LST without breaking the 2kg weight rule or straining their muscles.
Results: Precision Engine Casting
The company used this setup for the specific, high-stakes job of attaching engine block castings to metal plates so they could be cleaned. Once the cleaning was done, the team used water-filled hoses to check the castings for leaks. They currently use our battery powered torque tools at three different factories.
By using the LST with a balancer, the customer was able to ensure:
- Engine blocks were handled with precision.
- The assembly line stayed fast and efficient.
- Workers stayed safe and followed factory floor rules.
Why This Matters for Your Business
You don't have to be as big as an international auto company to care about efficiency, ergonomics and worker safety. Using the right tools with the right support systems can help your team work faster and reduce the risk of injury.
Key Takeaways:
- Think Light(er): Even heavy tools can be made "weightless" with the right setup.
- Follow the Rules: Safety rules like the 2kg limit drive safety innovation.
- Quality is Key: High-quality tools lead to high-quality engines.
