Case Studies & Success Stories

What these projects have in common

The details differ, the pattern does not. In almost every project we are called into, the original equipment was not badly made — it was specified against the wrong question. A bench was bought for its load rating when the failure mode was ergonomics. A flow rack was bought for its footprint when the problem was slope. The fix is usually cheaper than the original purchase.

Electronics assembly: the workstation that was too tall

The brief was a new assembly bench with ESD protection. The real problem, visible within ten minutes of watching the line, was height: the existing bench sat 900 mm high, comfortable for standing inspection and wrong for the seated fine work that occupied most of the shift. The new bench was built lower, with the ESD path designed in from the frame rather than added as a mat. Output did not change because the bench was better made. It changed because people stopped working around it.

Automotive components: a shelf that bowed at a third of its rating

A shelf rated 300 kg per level had taken a permanent set under roughly 80 kg. Nothing had broken: the tubes were straight and the joints intact. The load was concentrated in one spot rather than spread, and the panel between two supports was carrying a bending moment it was never designed for. The remedy was a centre rail, not a heavier bench — a piece of tube and two joints, and the shelf became roughly three times as stiff.

Warehouse picking: gravity that would not flow

Two lanes in a carton flow rack jammed every shift while the others ran cleanly. The rail was fine, the slope was fine, and the cause was carton condition — scuffed, slightly bulged bases on one supplier's packaging. Adjusting the lane for those boxes made the other lanes too steep. The workable answer was a separate lane for that SKU at its own slope, which is the sort of compromise a standard catalogue product cannot offer and a modular frame can.

What we will not claim

We do not publish invented savings figures. Every industrial project has a payback calculation, and the honest ones depend on your labour rate, your changeover frequency and your downtime cost, none of which we know. What we can state precisely is what the structure will carry, how it is assembled, and what it costs to change later. The rest of the business case has to be built on your numbers.

If you have a station that keeps generating complaints, send a photograph and a description of what fails. Diagnosing the real constraint is usually more valuable than quoting a replacement.