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Safety Gear Redesign
Hydraulic Jig Eliminates Heavy Lifting and Earns Innovation Award Nod
Downtime Reduced: Multiple hours saved per casting replacement
Manual Labor Eliminated: Hydraulic press replaced hammering process
Risk Mitigated: Heavy lifting and hammering fully removed
Award Recognition: Finalist, Nestlé Oceania Engineering Innovation Awards
The Challenge
At Nestlé’s large-scale production facilities, routine maintenance involved manually replacing heavy bronze bushes in large castings.
The existing method posed two critical challenges:
Occupational Health & Safety (OH&S) risk due to heavy lifting and hammering
Significant downtime due to manual removal and installation steps
Given Nestlé’s commitment to both safety and productivity, they needed a solution that was fast, safe, and scalable across the site.
The Solution
Alternative Engineering was engaged to design a custom solution that addressed both operational efficiency and OH&S risk.
AE engineered a bespoke jig that:
Nested the casting securely for safe handling
Integrated a hydraulic press to remove and install bushes without manual force
Allowed for quick positioning and operation, reducing overall process time
The design was delivered with full documentation, quality assurance, and implementation support to ensure smooth adoption across Nestlé’s team.
Outcome
| Metric | Result |
|---|---|
| OH&S Risk | Significantly reduced manual hammering & heavy lifting eliminated |
| Maintenance Time | Reduced by several hours per replacement cycle |
| Operational Disruption | Minimized across all teams |
| Internal Recognition | Finalist – Nestlé Oceania Engineering Innovation Award |
| Operational Efficiency | Scrolls supported higher-speed production with fewer faults |
| Team Adoption | Smooth site-wide implementation due to AE’s on-site professionalism |
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