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Forklift Assembly

Prior Solution:

A leading manufacturer of forklifts contacted SPIROL to help find a solution for an installation issue they were experiencing with Slotted Spring Pins used to retain two cast iron and steel components together. They were manually installing seven Slotted Pins per forklift with a hammer. In addition to production inefficiencies caused by interlocked Slotted Pins, the installation process created injuries on the assembly floor such as crushed fingers and repetitive strain injuries like rotator cuff tendonitis. In order to prevent these injuries from happening in the future, they understood that a change in both the fastener and installation process was needed.


SPIROL Solution:

SPIROL analyzed the application and assembly process and determined that standard duty SPIROL® Coiled Spring Pins would significantly reduce the insertion force. SPIROL also recommended the use of their CXA and CXD Pin-Driving Chucks and a pneumatic hammer rather than installing the pins using a traditional hammering method. In addition to alleviating the repetitive strain issue, the fact that Coiled Pins do not have a gap would eliminate the issues with the pins interlocking. Coiled Pins would also allow the manufacturer to widen their hole tolerances which would result in a 3X reduction in insertion forces as well as a reduction in the assembly process time.

Through comprehensive performance testing, the manufacturer validated the use of the Coiled Spring Pins over the previously used Slotted Spring Pins as well as the installation process with pneumatic hammers and SPIROL® Pin-Driving Chucks.

By partnering with SPIROL to find a solution to improve their assembly process and prevent injuries of their employees, the forklift manufacturer benefited from using a superior fastener, a faster and safer assembly process, as well as an overall cost savings. Using pneumatic force with SPIROL’s pin-driving chucks and wider hole tolerances rather than relying solely on the force of the operator’s arm with the tighter hole tolerances eliminated 1.8 million hammer blows per year and the costs associated with medical fees and lost time!

Complimentary Applications Engineering Support: SPIROL Engineers will review your application requirements and work with your design team to recommend the best solution at the lowest total assembly cost.