Watch the FlexErgo Part Manipulator in Action:
The challenge:
An operator reaching into a machine at chest height, repeatedly handling parts up to 50 pounds throughout an 8-hour shift.
The solution:
A custom-engineered machine tending lift assist arm, built by Flex Machine Tools specifically for a PM-33-A machine tending application.
The Problem: Repetitive Heavy Lifting in a Confined Workspace
In machine tending operations, operators must manually load and unload parts directly into or out of a machine. In this application, that meant reaching into the machine at approximately chest height to handle parts weighing up to 50 pounds, repeated throughout an entire shift.
A single lift may seem manageable. But sustained awkward reach combined with heavy load handling creates serious cumulative ergonomic risk. The Revised NIOSH Lifting Equation identifies horizontal distance from the body as one of the primary factors that multiplies strain on the lower back during manual lifts. The more a worker reaches to place or retrieve a load, the greater the injury risk, regardless of the load weight alone. The confined machine workspace left operators with no room to adopt a natural, neutral body position, compounding that risk with every repetition.
Beyond the physical toll, manual part handling introduces variability into production. Operator height, strength, and experience all influence how a part is placed, affecting process consistency and output quality from person to person.
The Solution: A Machine Tending Lift Assist Arm with Vertical
Shaft Gripper
Flex Machine Tools engineered a purpose-built FlexErgo Part Manipulator configured specifically for this PM-33-A machine tending application. Every element was designed around the actual working environment. It was not adapted from a general-purpose tool.
The core innovation is a pneumatic gripper mounted on a vertical shaft. This single design decision changes everything about the operator’s motion. Instead of reaching horizontally into the machine (the movement responsible for the ergonomic hazard), the operator positions the part above the target location and lowers it straight down. That vertical approach eliminates awkward reach, fits naturally within tight machine interiors, and delivers precise, repeatable part placement.
The result: one operator can confidently manage a 50-pound part with minimal physical effort, and every operator follows the exact same guided motion, every time.
What to Watch in the Demo
The video above demonstrates the arm’s full motion sequence: picking a part, lifting it, and placing it with smooth, guided control. While filmed in an open demonstration environment, this motion directly replicates how the arm operates inside the tighter, real-world machine workspace made possible by the vertical gripper design that eliminates the need for wide horizontal reach.
Why an Ergonomic Lift Assist for Machine Tending Makes
the Difference
Measurable ergonomic risk reduction.
Eliminating sustained awkward reach and repetitive heavy lifting directly addresses the root causes of operator fatigue and musculoskeletal injury. Operators finish shifts in better physical condition, reducing absenteeism and long-term workers’ compensation exposure.
Process standardization across all operators.
When a manual process depends on an individual’s physical characteristics, the process is only as consistent as that individual. The FlexErgo arm removes that variable entirely. Regardless of height, strength, or experience level, every operator follows the same guided pick-transfer-place motion, producing a consistent, repeatable result across all users on the floor.
Frequently Asked Questions
What is a FlexErgo Part Manipulator arm?
The FlexErgo Part Manipulator is a pneumatic lift assist arm engineered by Flex Machine Tools for industrial part handling applications. It is designed to reduce operator fatigue, eliminate awkward lifting motions, and standardize repetitive handling tasks on the production floor.
How much weight can the FlexErgo arm handle?
This custom configuration was built to handle parts up to 50lbs in a machine-tending environment.
What makes the vertical shaft gripper design different?
By mounting the pneumatic gripper on a vertical shaft, the operator can lower a part straight down into position rather than reaching horizontally. This reduces strain and makes the system effective in tight, confined workspaces where a traditional reach-and-place motion is not practical.
Can Flex Machine Tools build a custom solution for my application?
Yes. Flex Machine Tools designs custom part-handling and ergonomic solutions for a wide range of machine-tending applications. Find a solution that fits your application here.
