The challenge: Precision under pressure
At the CNH Industrial agricultural equipment manufacturing plant in Grand Island, Nebraska, Manufacturing Engineer Don Valalik faced a critical bottleneck. The facility was "up against a wall in terms of deadlines" for new production lines. The most significant challenge lay in the cornhead combine attachment area. Here, operators needed to install row unit modules weighing 1,000 pounds.
The existing infrastructure—an I-beam bridge crane with a hoist and spreader bar—was insufficient for the task. The heavy steel I-beams suffered from high inertia, making them difficult for operators to start and stop smoothly.
More critically, the system lacked the rigidity required to hold the heavy modules at the precise angle necessary for installation. Operators struggled to align the parts, resulting in a sluggish 20-minute installation cycle per module.
The solution: Rigid, low-friction handling
Valalik turned to a solution that had previously proven successful in the plant's spot welding areas: Gorbel® Work Station Bridge Cranes paired with GCI stacker manipulators.
For the critical row unit application, CNH specified a Gorbel® dual girder bridge system. Unlike the single I-beam, the dual girder design provided superior rigidity. This stiffness was essential for supporting the GCI stacker manipulator as it offset the 1,000-pound load. The enclosed track design of the Gorbel cranes offered a high amount of movement with low rolling resistance, allowing operators to move heavy loads quickly without fighting the crane's weight.
The execution: Standardizing for efficiency
The project involved a comprehensive upgrade across multiple stations to standardize the facility's lifting solutions.
- Mainframe assembly: A dual monorail system was installed to support two torque arms for tightening upper and lower mainframes on combines.
- Grain tank fabrication: A six-station cell was upgraded to improve flow and handling speed.
- Cornhead attachment: The dual girder bridge was deployed here to handle the massive row unit modules.
Visually, the installation introduced a cleaner, more organized workspace. The dual girders provided a stable platform for the complex GCI manipulators, eliminating the swaying and instability common with the previous I-beam setups. The modular design allowed the team to meet their "tough deadlines" without a problem. Valalik noted that because the systems are easy to install, they got them up and running with a "minimum amount of manpower".
The result: From 20 minutes to 5 minutes
The impact on productivity was immediate. By switching to the Gorbel dual girder system, the installation time for a triple row unit module dropped from 20 minutes to just five minutes—a 75% reduction.
Valalik noted that the new system allowed operators to maintain the required angle for installation effortlessly, overcoming the positioning issues of the old I-beam. Beyond speed, the upgrade improved safety and ergonomics. The lighter weight of the bridge reduced the effort needed to overcome inertia and start the crane in motion. Today, the Grand Island plant utilizes Gorbel products in over 15 different areas. Valalik stated, "We are very pleased with the performance of the Gorbel products".