The Problem
Our client needed to access a hinge to fit the hood on their production line for the manufacture of heavy plant. During this stage of production, the engine is exposed, at height and hot from a test performed earlier on the line. We provided this client with a repeatable and safe solution without disrupting the workflow.
The challenges
Our client needed to be able to access a hinge to fit the hood on their production line for the manufacture of heavy plant. During this stage of production, the engine is exposed, at height and hot from a test performed earlier on the line. We provided this client with a repeatable and safe solution without disrupting workflow. Other factors to consider were:
- There was a danger that the weight of a person on the lowest step would topple the stairs. Therefore, we implemented a counterweight which under responsible use they will not topple, in addition to adding a hard stop so that in the event of a topple, the stairs will move a minimal amount.
- Engineering a way of releasing the brakes. The specialised brakes did not come with any way of releasing, so we engineered a lever that could be compressed to release the brakes. These levers double as the handrail where it is easiest to push around the stairs.
- Maintaining a lightweight end product to ensure ease of use. For example, we manufactured the handrail using aluminium, and accurately calculated the sizes of steel plate and SHS to avoid introducing any weakness.
The Solution
Our solution was to manufacture a custom set of stairs on a set of castors to the following spec:
- An appropriate weight to be pushed back and forth.
- A protective plate enabling the operator to lean over the engine bay without risking falling off or exposure to the hot engine.
- Protective rubber buffers at appropriate height to prevent damage to the machine.
- Hand railing, steps, flooring, and kick plating to the relevant standards to prevent falls from the stairs.
- ‘Dead-man’s brake system’ to prevent the stairs from being able to roll whilst in use.
