Ergonomics in metalworking: safely handling heavy components
- Zeilhofer HHT
- 3 days ago
- 3 min read
Ergonomics in metalworking is becoming key to productivity and employee health. Sheets, plates, forgings, axles, and castings are heavy, often sharp-edged, and must be moved in large quantities—a combination of stresses that is difficult to manage manually over the long term. Manipulators up to 800 kg and theHub axle ZH90Lifting loads of up to 1,200 kg relieves the burden on employees and ensures tempo and quality.
Why ergonomics is particularly important in metalworking
Metalworking is among the industries with the highest ergonomic requirements. Characteristic features include:
High load weights from 25 kg to well over a ton per component.
Sharp-edged or slippery surfaces that make manual gripping risky.
High production volumes in 2- or 3-shift operation over many years.
Component geometries vary depending on the order and variant.
Heated or oily components from upstream processing steps.
Consequently, musculoskeletal disorders are among the most frequent causes of absenteeism. Ergonomic lifting aids are not a luxury in this context, but a prerequisite for efficient production.
Typical applications for lifting aids in metalworking
Sheet metal and plate handling before and after punching, laser cutting and welding systems.
Remove forged parts from the press and send them for post-processing.
Workpiece feeding of CNC machining centers with axes, shafts and flanges.
Transfer large cast components from the cleaning shop to the final processing stage.
Ergonomically pick semi-finished products in the warehouse and goods receipt area.
Ergonomics of metalworking withmanipulatorand lifting axis
The Joint manipulatorIt moves components weighing up to 800 kg smoothly and with a large working radius. The ZH90 lifting axis lifts up to 1,200 kg on the linear Z-axis, ideal for the heaviest forged and cast parts. Mobile lifting platforms with a 48-volt battery support workshop and maintenance operations without a compressed air connection.
The gripping mechanism is crucial: individual grippers with magnets, vacuum, clamping jaws or special devices are precisely designed for the component and surface, even with hot or oily workpieces.
Efficiency and compliance
A lifting aid reduces downtime by decreasing physical strain, minimizes rejects on sensitive surfaces, and increases throughput per operator. At the same time, it meets the ergonomic requirements of the manual handling regulations and the upcoming EU Machinery Directive 2027.
Individual design from a single source
Every metalworking workplace is different. That's why Zeilhofer develops each solution individually: engineering, design, manufacturing, commissioning, and service all from a single source in Holzkirchen. ISO 9001 certified, TISAX Level 2 with prototype protection.
Have the process analyzed
Do you want to handle heavy metal components ergonomically and reduce downtime? We analyze your process and develop a suitable lifting aid. Request a free consultation now.
Frequently Asked Questions (FAQ)
Which components are lifted manually in metal processing?
Typical examples include sheets and plates, forgings, axles, castings, shafts, and semi-finished products weighing from 25 kg to well over a ton. If these components are lifted frequently or held in an awkward position, they should be placed on a lifting aid rather than handled by employees.
Why is ergonomics particularly critical in metalworking?
Metalworking involves high production volumes combined with heavy loads and often sharp or slippery edges. The proportion of physically demanding tasks is above average, and consequently, so is the risk of musculoskeletal disorders.
Which lifting aids are suitable for forging and machining operations?
For stationary workstations, manipulators up to 800 kg and the ZH90 lifting axis up to 1,200 kg. MobileLiftThe e can be supplemented with a 48-volt battery for workshop and maintenance tasks. Individual grippers and magnetic holders are designed for component geometry and surface finish.
How quickly does a lifting aid pay for itself in metal processing?
For heavily used lifting workstations, savings are often achieved within 12 to 18 months. This results in reduced downtime, fewer scrap items due to damage, and less time spent tying up personnel to heavy loads. Specific calculations are performed as part of the process analysis.
