OVERVIEW 
A Tier-1 automotive components manufacturer operating a high-volume automotive assembly line relied on manual chain hoists to lift engine blocks weighing 450-750kg.
As product volumes increased, operators experienced fatigue, slower cycle times, and inconsistent load positioning.
To improve efficiency and safety without altering existing rigging practices, the manufacturer evaluated upgrading to electric chain hoists compatible with their current chain sling systems.
CHALLENGES
- Manual lifting speeds limited to 1-2m/min, slowing cycle times
- High physical effort required for repetitive lifts throughout each shift
- Increased risk of musculoskeletal injuries - over 36% of workplace injuries are linked to overexertion
- Poor load control causing uneven sling loading and accelerated wear
SOLUTION
The facility replaced manual hoists with 1-2 tonne electric chain hoists, retaining their existing alloy chain slings. The upgrade required no structural changes and minimal operator training.
Electric hoists delivered consistent lift speeds of 6-10m/min, smoother load handling, and improved positioning accuracy at each workstation.
BENEFITS
- Increased Productivity: Lift and positioning time reduced by 42%, while assembly throughput increased by 8-10% per shift.
- Faster ROI: The higher upfront costs of electric chain hoists was offset in under 14 months through improved productivity, reduced injuries, and lower sling replacement costs.