report
Mission report
Ergonomics is taken into account right from the planning stage of the facility
A standard lift table as a custom-integrated production solution.
ZORN Präzision Maschinenbau stands for sophisticated, customized solutions in the micro-scale range. The company develops and manufactures special-purpose machines for micro-automation and micro-assembly. A particular area of expertise for ZORN is the production of specialized machinery for the precision assembly of components involving wire and glass. Since 2015, ZORN has offered the "ZORN microone"—a compact, modular precision machining center designed for the milling, drilling, and grinding of miniature parts.
This small machining center features a deliberately space-saving design, requiring a footprint roughly equivalent to the dimensions of a Euro-pallet. Its modular structure is divided into two main sections: the lower supply module and the machining module positioned above it.
What ensures a compact footprint for the future customer poses a particular challenge for employees during production. This is because the machine must be easily accessible along its entire height during assembly.
Different mounting heights on a single machine
If the machine is placed directly on the floor of the production hall, components of the supply module are at a very low working height. To assemble them, the employee would have to repeatedly bend down, kneel, or work in an awkward posture for extended periods of time.
The opposite situation arises at the upper processing module. Some areas are so high up that they can only be reached with outstretched arms or with the help of a ladder.
Both work positions place a strain on the body and make it difficult to perform the assembly process safely and with full concentration. In addition, the required working heights change repeatedly during production. A fixed assembly station cannot accommodate these varying requirements.
THE VIDEO REPORT
We visited ZORN Maschinenbau GmbH and observed the lift table during the ongoing assembly process.
In the video, we show how the machine is moved to different heights and how the employee works at the feeding and machining module.
The ZORN Maschinenbau Double-Vertical TL Lifting Table supports:
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Wide usable stroke range
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Electrohydraulic Height Adjustment
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Precise positioning under load
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Less bending over and working above shoulder height
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Less Work on the Ladder
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Customized Integration into Production
TL lifting tables, double vertical
The solution starts with the gym floor
When planning the new production building, ZORN therefore took ergonomics into account from the very beginning. A pit was specifically incorporated into the floor of the production hall. An electrohydraulic TL double-vertical lift table from Beck was integrated into this pit.
During assembly, the machine stands directly on the lifting table’s platform. Depending on which module is being worked on, it can be raised or lowered. This ensures that the employee does not have to work at varying heights. Instead, the machine is moved into the position appropriate for each work step.
Positioning with millimeter precision—as often as necessary
The electrohydraulic height adjustment allows for convenient operation at the push of a button. The machine’s position can be adjusted precisely even under load. When working on the lower supply module, the lifting table raises the machine. This brings the relevant components into an easily accessible work area. This reduces the need to work in a bent-over position.
To install the upper machining module, the machine is lowered accordingly. The employee can reach the components from the shop floor and does not need a ladder for many work steps. This height adjustment can be repeated as often as needed throughout the entire manufacturing process. This ensures a suitable working position for each assembly step.
Standard Technology Intelligently Integrated
The TL Double-Vertical Lifting Table used here is essentially a tried-and-true product from the Beck lineup. What makes this a unique solution is its customized integration into the production environment.
The recessed base ensures that the lift table can be lowered significantly without its overall height interfering with the work process. At the same time, the vertically doubled scissor mechanism provides a wide lifting range.
This solution thus offers two key advantages: The compact machine can be positioned very low and raised high when necessary.
The example from ZORN shows that not every customized solution requires a completely new product. What is often crucial is taking a holistic view of the product, the building, the workflow, and the people who work at that location.
Ergonomics starts with the planning phase
The project at ZORN clearly demonstrates the potential that arises when ergonomics is taken into account early on. This eliminates the need to retrofit the workplace to existing conditions later on. Buildings, technology, and workflows can work together effectively from the very beginning.
The result is a modern assembly solution that combines reduced physical strain, good accessibility, and an efficient manufacturing process.
Are you planning a new production area or looking to ergonomically optimize an existing assembly station? Together, we’ll develop a lift table solution that’s tailored to your product and your workflows.
Get a no-obligation consultation now:
Florian Schmolke
Sales
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