Elevating production efficiency with vacuum lifters
Continental Tires adopted vacuum lifting technology, tailored to the unique challenges of handling tires and wheels
Our everyday life has become very different compared to how it was before. We used to lift manually and always got very tired during the day since we lifted so many kilos. Now we don't have to lift manually any more. It's really fantastic!
Roger Tangen
Production Worker
Elevated production efficiency and employee satisfaction at Continental Tires
In the dynamic world of automotive parts logistics, production managers face many challenges, from ensuring employee safety to optimizing efficiency. Continental Tires in Norway, under the management of Trygve Gjessing, exemplifies a forward-thinking approach to overcoming these obstacles through the adoption of TAWI vacuum lifters.
Background: Continental Tires Norway operates a central warehouse, also incorporating a wheel assembly operation for new vehicles in Norway. With an annual production ranging between 100,000 to 200,000 wheels, and up to 1,000 wheels on peak days, the demand on employees is significant. The shift towards electric vehicles has seen wheel sizes, and consequently their weight, increase, with an average wheel weighing 28 kg—well above recommended individual and daily lifting limits.
Production efficiency challenges:
- Increased physical strain: The larger and heavier wheels for electric vehicles posed a significant physical strain on employees, leading to potential injuries and higher absenteeism.
- Ergonomic and safety concerns: Manual handling of these heavy components exceeded the advised limits set by workplace safety regulations. This necessitated a re-evaluation of lifting practices.
- Efficiency bottlenecks: Traditional lifting methods were not sustainable for the volume and weight of wheels being handled, impacting overall production efficiency.
Production efficiency solution: TAWI vacuum lifters
Upon recognizing these challenges, Continental Tires explored various lifting solutions, ultimately integrating TAWI vacuum lifters into their operations. A customized vacuum tool was developed to ensure that the employees could handle the wheels in an efficient and ergonomic manner. This technology enabled a drastic reduction in physical lifting requirements. Material handling went from approximately 900 kg per wheel set to less than 30 kg in total process lifting weight.
“We have team members who have worked in assembly for several decades and it’s evident that such long-term commitments take a physical toll. Our objective is to substantially improve the workplace environment and create a more efficient production process” says Trygve Gjessing, Head of Nordic Supply chain design and complete wheels, Subregion Nordics.
Key efficiency benefits:
- Dramatic reduction in physical strain: The implementation of vacuum lifters has significantly eased the physical demands on employees. The workplace has become safer and more inclusive.
- Enhanced safety and ergonomics: By minimizing manual lifting, the risk of injuries and compliance with safety regulations has improved. This contributes to a healthier work environment.
- Broader workforce recruitment: The reliance on physical strength has been reduced. This allows for a more diverse workforce and potentially lowering absenteeism due to injuries.
- Long-term employee well-being: With some employees having decades of service, the focus has shifted towards ensuring their health and longevity in the workforce.
Results: improved production efficiency and employee satisfaction
The move to a new warehouse in 2010 provided an opportunity to reimagine lifting and handling processes. Inspired by TAWI’s solutions seen in other industries, Continental Tires adopted vacuum lifting technology, tailored to the unique challenges of handling tires and wheels.
This adaptation has not only transformed their operational capabilities but has also been met with overwhelmingly positive feedback from employees. Production worker Roger Tangen, highlights the stark difference in daily work life and the elimination of heavy manual lifting.
“We have received good lifting equipment, really great. Our everyday life has become very different compared to how it was before. We used to lift manually and always got very tired during the day since we lifted so many kilos. Now we don’t have to lift manually any more! It’s really fantastic”, says Roger Tangen, Production Worker at Continental Tires, Norway.
A safer, more inclusive and efficient workplace with vacuum lifters
For production managers navigating the complexities of modern manufacturing and logistics, the case of Continental Tires in Norway serves as an example of how innovative lifting solutions can address ergonomic, safety, and efficiency challenges.
By adopting TAWI vacuum lifters, Continental has not only improved its operational capabilities. The company has also taken significant strides towards creating a safer, more inclusive, and efficient workplace.
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