Page 30 - MetalForming August 2019

FABRICATION
New Press Brake Designs
Tackle Ergonomic Concerns
Stand/sit options, tool proximity, lighting and more improve operator comfort and reduce injury risks, translating to less waste and greater throughput in small-part production.
BY VINCENT IOZZO
Ergonomics in the workplace remains a highly discussed topic, and a quick Google search reveals hundreds of studies and recommenda- tions for desk chairs, tables and moni- tors. But often overlooked, these same conditions apply to manufacturing envi- ronments as well. In fact, the ergonom- ics of a production operator is more critical to a business than you may think.
Ergonomics is defined by Merriam Webster as “an applied science con- cerned with designing and arranging things people use so that the people and things interact most efficiently and safely.” More simply, ergonomics
Vincent Iozzo is product manager-bend- ing for Trumpf Inc., Farmington, CT; www.trumpf.com.
involves designing or modifying work to fit the worker in order to eliminate discomfort and injury. Though some might see this as a luxury, the imple- mentation of workplace ergonomics repeatedly has been linked to higher efficiency and profitability.
A Demanding Task
Press brake operation represents one manufacturing task with a very high safety risk. A press brake’s main goal: Perfectly repeat a series of move- ments to ensure high-quality produc- tion. During an ordinary shift, a press brake operator may repeat the same cycle of movements hundreds of times. This type of repetition places operators at high risk for multiple types of short- and long-term injuries. Many busi-
nesses understand that the biggest risk to productivity comes from employee absence, but not enough understand that most injuries result from a repet- itive strain, Furthermore, studies show that sprains and strains comprise more than 40 percent of workplace injuries.
Ergonomic improvement tends to focus on large- or heavy-part production, which seems to be the most obvious way to increase productivity or reduce injury during press brake operation. But an equal focus should be placed on small-part production, defined here as parts weighing less than 25 lb. and with forms less than 50 in. long. Experience has shown that large press brakes do not form small parts effectively, with operator ergonomics representing the most critical disadvantage. Though larg-
Smaller-sized press brakes now are being designed with ergonomics in mind. These new breeds enable operators to stand or sit, and tool storage at the machine enables quicker, easier and safer changeovers.
28 MetalForming/August 2019
www.metalformingmagazine.com