2022 ERGO CUP WINNER
Manual movement of 5-gallon pails is a leading cause of injuries in AC stores (9 I&Is in 2021). Employees working in AC stores are required to routinely lift 5-gallon pails, which weigh approximately 55 lbs., to stock inventory, tint containers to match color specifications, and deliver product to customers. The lift assist units are a purpose-designed tool that was jointly developed by PPG and Radia to cost effectively move pails during tinting operations in paint stores. The lift assist takes the weight and reduces to the 55 lb. lift to feel like less than 1 pound.
Innovation
This device was jointly developed by Radia and PPG. PPG approached Radia with the problem and collaborated with their engineers to work toward a solution. This project spans over 3 years, and PPG aided in the design, as well as all testing. Testing was done at multiple PPG store locations.
Simplicity
This project requires the installation of a jib crane behind the tint line. The crane comes already built and it requires bolting the crane into the floor. Once completed the crane can reach any area in the tint line and eliminates the manual lifting. Lifting using this device is nearly as fast as lifting by hand. There is also a version that ties right into the shaker, this is for smaller store footprints where a crane is not feasible.
Ergonomic Risk Reduction
Lifting pails to and from the tint line conveyer results in an over 40% - 70% increased risk of an back injury. About 10% of all injuries in stores and about 14% of workers compensation cost occur during tinting operations. Implementation of the lift assist should essentially eliminate the risk of a back or shoulder injury when transferring pails to or from the tint machine.
Cost Savings / ROI
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Injury reductions
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Lower workers' compensation cost
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Lower replacement labor
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Improved employee retention
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Increased available labor pool
Project cost - $8,900 per store
Incident cost avoidance - $175,000 per year
Sustainability
To date, the system has been installed in 40 stores in the US and Canada and in those stores we’ve experienced zero injuries in terms of back strains, or shoulder injuries.
Five Gallon Lift Assist EMPLOYEE TESTIMONIALS
Dan Powell
SENIOR MGR TRADE OPERATIONS - AC, PPG PAINTS
This is really a simple solution, requiring the installation of either a jib crane or a cage around one of your existing 5 gallon shakers.
David Neal
DIRECTOR OF ENVIRONMENT, HEALTH, & SAFETY - USCA, PPG PAINTS
About 25% of injuries in our stores occur during tinting operations, and about 40% of those injuries are a back or shoulder strain.
Dave Grom
STORE MANAGER, PPG PAINTS
We've moved at least 100-200 pails per day with the lift system. I can see that using it greatly reduces the strain on the employees' daily activities. It's, by far, a great tool and an efficient one, as well.
Jonathon Rutkowski
STORE EMPLOYEE, PPG PAINTS
With the lift assist, I know that it’s a big help having the equipment around. It will save my lower back.
Blake Litsey
STORE EMPLOYEE, PPG PAINTS
In our store, we lift multiple five-gallon buckets daily...Many times, multiple pallets worth of paint. Having a sore back even with proper lifting technique was a common daily occurrence. In my opinion, a lift assist is the greatest investment that could be added to a store to help prevent back injuries.