Why Were ILDs Invented?
The invention of intelligent material handling devices was driven by a pressing need. In the 20th century, globalization and advancements in communications technology accelerated business operations to unprecedented speeds. Orders could be placed, produced, and shipped faster than ever before. However, this surge in productivity also led to a rise in workplace injuries and workers’ compensation claims.
Automation provided a solution for some industrial tasks, but many operations still required human precision and dexterity. To address this gap in safety and technology, engineers began developing new lifting technologies. Gorbel® was the first company to bring technology of this kind to the US material handling market, offering the G-Force® Intelligent Lifting Device in 2000.
Like many breakthrough technologies, the G-Force® initially encountered market resistance, largely due to the challenges of integrating new systems and training personnel. G-Force® early adopters, however, began to see measurable benefits as the devices proved their value in real-world operations. This set the stage for Gorbel® to take a closer look at the tangible results ILDs have delivered, particularly in addressing one of the industry's most persistent issues – injuries caused by lifting and moving tasks. According to the Material Handling Institute (MHI), these tasks still account for 60% of industry-related injuries.
Want to learn more about the early engineering and development of the
G-Force® Intelligent Lifting Device?
Quantifying the Impact of ILDs
Gorbel® has published a variety of studies that are available for free download along with various helpful guides and technical documents. These resources dive into the specific features, benefits, and applications of ILDs.
In one study, Gorbel® recruited the Rochester Institute of Technology (RIT) to compare the performance of a G-Force® Intelligent Lifting Device to a variety of traditional methods. Their engineers designed a series of tests that mimicked real-life material handling situations. Participants were outfitted with heart rate monitors, then asked to complete lifting tests using different methods. Traditional methods included an air balancer with pendant control, a variable-frequency-drive chain hoist, an electric balancer, and an air balancer with electric controls.
Precision-Placement Test Results
Many precision-placement applications require placing a load as gently as possible to prevent product damage. To simulate this in the test environment, participants were asked to pick up a 45 lb. weight and place it on a tabletop target three feet away. Underneath the target was a force plate that measured the force at impact.
According to their results, the G-Force® Intelligent Lifting Device was 3.3X less likely to damage the load than the other lifting methods. Two key features enabled the G-Force® to excel in this test – the ability for the operator to set slowdown points, and the device’s sensitivity small amounts of force.
Every ILD has unique engineering and there is no one-size-fits-all ILD. Any application will present unique variables and needs. It is important for prospective buyers to consider all the ILD options and carefully weigh each device's features and special advantages.
The Long-Term Financials of ILDs
The initial investment in ILDs is often higher than that of traditional methods like hoists and air balancers because advanced technology requires a more intensive manufacturing process. Despite the upfront cost, the long-term benefits of ILDs can justify the investment. Some mid-size companies that implemented ILDs have seen a return on investment (ROI) in just a few months. Gorbel® maintains an extensive library of case studies that feature exact ROI figures for many applications.
One of the most impactful long-term cost reductions that ILDs can provide is a reduced injury rate. The control and assistance provided by ILDs mitigates both accidental and cumulative injuries. Cumulative injuries can be understood as those caused by the effects of physically repetitive motions like bending, reaching, stooping, and twisting that compound over time. In some applications, ILDs can virtually eliminate repetitive motions and in turn increase the overall quality of life for an employee.
The benefits of a happy and healthy workforce are exponential – improved worker morale, lower insurance costs, reduced work stoppages, medical claims, and absenteeism for starters. The ergonomic advantages of ILDs also make jobs in the material handling industry more accessible to a broader workforce since anyone can operate one regardless of their age, weight, or gender.
The Future of Ergonomics and Productivity
ILDs have earned their place as a strategic investment that delivers tangible returns in terms of safety, productivity, and profitability. These devices can already be found in a wide variety of sectors – automotive assembly, aerospace, heavy machinery production, loading docks, palletizing, and the gas and oil industries to name just a few.
Gorbel® invites you to read the full version of the study referenced in this article, The ROI of ILDs: How Intelligent Lifting Devices Are Paying Dividends...