A regional fulfillment center, currently in the process of constructing a new warehouse to store inventory, required a significant number of custom concrete embeds. Specifically, they needed 1,010 embed plates, each measuring 6” x 24” and fabricated from ½” thick steel. The plates are to be used as anchor points for the exterior walls of the building and cast into the concrete deck slabs.
Each embed plate is also customized with two welded studs to ensure a secure connection. With tight deadlines and strict quality standards, this project required precision and efficiency in production.
Challenges of Mass Producing Weld Plates
The production of over 1,000 steel embed plates in a short time-frame presented several challenges. First, the size and weight of both the embed plates and the equipment required to weld the studs onto them posed difficulties for our team. The stud welding gun and its attached cables were heavy and had limited mobility, leading to operator fatigue. Over time, this fatigue could result in reduced productivity and inconsistencies in weld quality. Additionally, the repetitive nature of the work heightened the potential for strain on our employees, increasing the likelihood of injury and compromised product integrity.
- Heavy Unwieldy Equipment and Cabling
- Lack of Equipment Mobility
- Worker Fatigue from Equipment (Over)Handling
- Decrease in Quality Over Time
Devising a LEAN Manufacturing Solution for Fabrication of Embed Plates
To overcome these challenges, Eberl Iron Works applied its expertise in LEAN manufacturing principles. Our team of skilled workers, all trained in LEAN methods, was tasked with finding a solution that would increase efficiency and reduce worker strain during this and future projects for large quantities of concrete embeds or other stud welding products. But before we dive into the specific solution we developed, it’s important to first understand what LEAN manufacturing entails.
What is LEAN in Manufacturing?
LEAN manufacturing is a systematic approach to improving processes by eliminating waste and optimizing efficiency. Key principles of LEAN include:
- Value: Identifying what adds value from the customer’s perspective.
- Value Stream: Mapping out all steps involved in the production process.
- Flow: Ensuring that production processes run smoothly and without delays.
- Pull: Producing only what is needed, based on demand.
- Perfection: Continuously improving processes to achieve better results.
Now that we understand more about LEAN, let’s talk about how we developed and implemented a strategy to overcome the fabrication challenges in our project for manufacturing over 1K concrete embeds. To address the issues of operator fatigue and limited mobility during the stud welding process, our team engineered a custom solution: a Unistrut Gantry system.
What is a Gantry?
A gantry is a structural framework used to support and transport heavy loads, particularly in industrial settings. In the context of stud welding, a gantry is often employed to suspend equipment, like welding guns and cables, making them easier to manipulate. Traditional stud welding involves manually lifting and positioning the heavy welding gun, which can be cumbersome and lead to worker fatigue. With a gantry system in place, the equipment is suspended overhead, and can be moved effortlessly along the work area using trolley systems. This allows operators to focus on precision and speed, rather than being burdened by the weight and restricted movement of the tools.
This gantry was specifically designed to attach to an overhead beam and integrate seamlessly with our stud welding table, allowing us to suspend the heavy welding cables and gun above the workspace. By incorporating Unistrut Trollies into our gantry design, we enabled smooth, overhead movement of the cable system, giving operators significantly more freedom of motion.
This minimized the strain on our employees, from repetitive handling of equipment over long periods, and ensured that the welding process could be performed consistently and accurately. The system not only enhanced productivity by reducing operator fatigue but also helped equipment operators to maintain the high quality standards required for the project, and to complete the project in less time.
The custom Unistrut Gantry system we designed for this project provided the perfect solution, improving both the efficiency and safety of the stud welding process for the production of concrete embeds.
For more about the solution we built for this job
CLICK THE LINK > Designing and Building a Custom Unistrut Gantry for a Stud Welding Workstation
How to Install Concrete Embed Plates
Once fabricated, embed plates must be installed into the concrete decking during the construction phase. The plates are placed into formwork before the concrete is poured, ensuring that the studs are positioned to secure the exterior walls. The precise alignment of these plates is crucial, as they will serve as the primary anchor points for the structure’s walls. Contractors need to ensure that the embed plates are securely held in place during the pour to prevent any shifting, which could impact the integrity of the connection.
What Types of Steel Embed Plates Do We Offer?
At Eberl Iron Works, we offer a variety of steel embed plates, including tie plates and weld plates. Both types are available in multiple sizes, materials, and finishes to suit different applications. For more information about these products, click on the links below to learn more about their specifications and how they can meet your project’s needs.
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