“Necessity is the mother of invention.”
While Internet memes may assign that quote to Albert Einstein, the truth is no one knows for certain where this proverb came from. It has certainly rung true through the ages. In fact, there are records of it being uttered as far back as 1519! There is more than a kernel of truth in its wisdom.
Hirschvogel Incorporated is a subsidiary of the Hirschvogel Automotive Group, a German company. Founded in 1988, Hirschvogel Incorporated (HVI) produces a mixture of cold and warm forged parts in its Columbus, Ohio facility. Since 2006, it has followed in the footsteps of Hirschvogel Komponenten GmbH by offering, according to its website, “machining of forged parts, some of which are supplied ready-for-assembly.” Suffice it to say, it’s a busy factory!
In mid-2016, HVI found itself looking for a way to store more goods while also freeing up space for non-storage purposes within its dye prep area. At the time, it was using conventional rack shelving. Growth and increased productivity – both great things – were creating a need for a bit of innovative brainstorming.
Jason Cudak is a project manager at the Columbus facility. He knew that some of the other facilities in the company had decided to utilize vertical carousel systems. Given that the ceilings in the Columbus facility topped out at just 15 feet, however, the idea seemed inadequate for HVI’s needs.
“We loved the potential of the vertical carousel and were pretty much sold on its upside early on,” said Cudak. “At the time, we had started to process more goods and space was becoming increasingly valuable. Despite our relatively low ceilings, we knew that to get the most bang for our buck we needed to go as high as we possibly could.”
Thinking outside the Box
While raising the ceiling throughout the plant was of course out of the question, there was another option that, while unconventional, resulted in an “a-ha moment” for Cudak, Patterson Pope Sales Representative Eric Martin, and the rest of the team. They didn’t really need to “raise the roof” at all. Instead, they could simply add the vertical carousel to the outside of the building.
“In order to get to a more appropriate height, we knew we’d have to install it outside the wall,” said Cudak. “We decided on the Lean-Lift from Hanel, and that’s exactly what we did.”
In fact, the Hirschvogel team opted to install three Lean-Lifts – two measuring 35 feet tall and one a towering 53 feet. As luck would have it, installation of the trio ended up occurring in the middle of an Ohio winter. That, in and of itself, presented a number of challenges.
“The initial plan was to install the Lean-Lifts first, then build the encasements around them,” said Martin, “but it couldn’t be done that way because with their height, you needed something to ‘tie’ them to at their apex. On the other hand, we couldn’t have them build the building before we installed the equipment because there’d be no way to get it erected within that small space.”
Dilemma.
“We had to partially install the framework of the addition, then put some of the Hanel unit in, then complete the addition, and finally finish the product installation,” explained Cudak. “There were a lot of steps involved and a lot of coordination.”
“It was definitely nice to be able to work with a company that was committed to seeing the project through to the end and to have it be successful. I’d definitely recommend Patterson Pope. They listen, and they’re all about helping you find more than just ‘a solution.’ They’re committed to helping you find the right solution.”
A Focused Effort
Many of us are familiar with the unofficial motto of the United States Postal Service:
“Neither snow nor rain nor heat nor gloom of night stays these
couriers from the swift completion of their appointed rounds.”
That’s one dedicated bunch! As it turned out, the Lean-Lift installation gave the USPS’s staunchest stalwarts a run for their money when it came to battling nature’s more temperamental side. Wind, sleet, snow and rain provided an ample challenge for the team; a challenge that was met and conquered. Rising like chimneys next to the facility, the three lifts are protected against the elements by pre-engineered metal buildings with steel columns and engineered siding.
Cudak appreciated Patterson Pope’s attention to detail, and the willingness to be flexible. “Patterson Pope really listened to us and paid attention to what we needed,” he said. “They weren’t just pitching us a price and a product; it was really a process designed to select and install what was right for us. It made a big difference.”
Reacting to constantly changing storage demands can always be challenging. Situations, needs and work areas are always in flux. Being able to meet those demands head-on – and react with speed and precision – is what sets Patterson Pope apart.
As a result of the installation, Hirschvogel Incorporated was able to shrink its dye prep area, creating additional storage for goods. That, in turn, allowed them to install a new furnace for part processing, as well.
“It was definitely nice to be able to work with a company that was committed to seeing the project through to the end and to have it be successful,” added a satisfied Cudak. “I’d definitely recommend Patterson Pope. They listen, and they’re all about helping you find more than just ‘a solution.’ They’re committed to helping you find the right solution.”
That’s inventive.
For more information on this project, please visit our Case Study.
