The customer’s assembly line required installing large, heavy bumpers on trucks at a specific stage of production with limited floor space. The existing process relied on an overhead crane to precisely position the parts.  The hoist presented multiple safety risks and was difficult to precisely or efficiently position the part for bolt installation.

The bumper was suspended by hook attachments, leaving multiple potential failure points that could result in a catastrophic drop.

The major safety concerns included:

• Multiple near-miss incidents had occurred with the crane-based system.
• The load was freely suspended with no mechanical lock, meaning any single failure point could cause a dropped load.
• Operators were required to be in close proximity during installation, exposing them to serious injury risk.

The customer also faced a secondary challenge: their line handles eight different bumper configurations with varying sizes, shapes, and center-of-gravity positions. A replacement system needed to accommodate all variants while allowing precise final positioning that a standard directional transporter could not achieve.