The Case Study We Never Meant to Write: A 62.5% Loss in Productivity

At Obsidian Manufacturing Industries, Inc., we don't just produce MagnaLift & Power-Grip lift magnets; we use them every single day. Our surface grinding services, primarily based on large-capacity needs, rely on our own magnets to safely and efficiently load materials.

We always knew they were critical, but we never had the hard data to prove it until now.

We rely on our trusty MagnaLift lift magnets consistently in the shop to decrease safety risk and increase productivity.

The "Accidental Experiment": Our Main Tool Disappears

The old adage "you don't know what you have until it's gone" became our reality when our overhead crane was recently down for maintenance. While our magnets were fully functional, the crane outage meant we couldn't use them in the way they were intended.

This immediately crippled our ability to load our 84” and 54” rotary grinders and our 96” horizontal grinder, which collectively represent about 95% of our surface grinding capacity.

Overnight, we were forced to revert to the "old way." While smaller parts could be loaded by hand, our larger, heavy-plate jobs required forklifts and/or cumbersome rigging straps. This process was so inefficient that we had to refuse new jobs, had work pulled due to longer lead times, and lost our profitability on repeat jobs because we couldn't load the material safely or profitably.

The before-and-after results were staggering. We were taking 3x longers loading our grinders, a cost that completely erased any profit on our most common, repeat jobs.

The Data: Lift Magnet vs. Manual Rigging

We compared the time studies for one job we have done with and without lift magnets: two side grinding six large plates on our 84" rotary grinder. The data from this "accidental test" speaks for itself.

Metric	With MagnaLift Magnet (Normal Ops)	Without Magnet (Forklift/Straps)	The Impact
Job	6pcs, 73.5” x 28.25” x 2.375” grind to 1.968"	6pcs, 73.5” x 28.25” x 2.375” grind to 1.968"	--
Load/Unload Time	15 min per piece (avg)	45 min per piece (avg)	3x Increase in Handling Time
Operators Required	1	2	100% Increase in Labor Cost
Total Job Setup Time	40 min per piece (avg)	90 min per piece (avg)	2.25x Increase in Setup Time
Jobs per Shift (Est.)	8	3	62.5% Loss of Throughput
Safety Process	Operator is clear of load	Operators in proximity to load, forklift, & straps	Increased Operational Risk
Job Profitability	Typical Profit	LOSS	Direct Bottom-Line Effect

One of our Power-Grip LB-15G lift magnets loading a table on our 84" surface grinder

The Hidden Costs of Manual Material Handling

The time study in the table only tells part of the story. The actual cost and potential costs of not having our magnets were even higher.

1. Lost Revenue and Damaged Lead Times

During the time our crane was inoperable, we lost two existing jobs that were already in our shop because the increased handling time destroyed our quoted lead time. We also had to refuse at least one new, profitable job because we simply could not safely or efficiently load the material.

2. Increased Operational & Safety Risk

Safety is paramount and MagnaLift & Power-Grip lift magnets are designed to decrease safety risks. Any different process, like using straps or forklifts for loads we would typically use a magnet for, introduces operational risks. This less-controlled method required our team to work in close proximity to the workpiece and lifting equipment, creating potential for pinch points or other hazards—all of which are eliminated by the "hands-off" nature of a magnetic lift.

3. Risk of Material Damage

Loading heavy, precision-ground plates with forklifts and straps introduces a significant risk of damaging the material. Straps can create single points of pressure, and forklift tines can easily scratch or chip a finished surface. The even, distributed pull of our lift magnet on the material's surface avoids this damage entirely.

Fleets of Power-Grip lift magnets can greatly increase your ability to safely and efficiently move material, whether it be on and off the machines in machine shops or in and around steel mills or distribution centers.

The Verdict: A Magnet's True ROI Isn't Just Speed

This "accidental experiment" was a powerful, real-world confirmation of our product's value, which directly impacted our own bottom line. We proved that our MagnaLift & Power-Grip magnets are not just a "nice to have" convenience; they are a core component of our shop's profitability, throughput, and safety.

Losing them for just a few days doubled our labor costs, slashed our throughput by over 60%, and turned profitable jobs into losses.

Are you still relying on straps and forklifts to move your material? Contact our team for a productivity and safety assessment to discover how this data can be applied to your shop floor.

Obsidian Manufacturing Industries, Inc. is a family-owned, certified WOSB manufacturing company and is the OEM for Magna-Lock USA workholding, MagnaLift & Power-Grip lift magnets, and Arter Precision Grinding Machines, as well as providing surface grinding services. They are located at 5015 28th Ave. in Rockford, Ill. with a phone number of 815-962-8700. Check out more at obsidianmfg.com/brands.