Introduction
Manufacturing facilities require reliable access equipment for maintenance, installation, and renovation work. This case study examines how a large manufacturing plant in Poland achieved an impressive safety record and improved operational efficiency by investing in Zoomlion boom lifts from GMH Lift.
Client Background
Company: Central Europe Manufacturing Sp. z o.o. (name changed for privacy)
Location: Warsaw, Poland
Industry: Automotive parts manufacturing
Facility size: 120,000 square meters
Workforce: 1,800 employees across 3 shifts
Challenge: Maintaining production equipment, overhead cranes, and facility infrastructure while maintaining zero-accident target
The Challenge
Central Europe Manufacturing faced several operational challenges:
- Safety priority: Corporate target of zero recordable incidents
- Complex facility: Multiple production halls with varying ceiling heights (8-18m)
- Diverse applications: Equipment maintenance, lighting replacement, crane inspection, HVAC servicing
- Production pressure: Minimal downtime windows between shifts
- Harsh environment: Welding fumes, metal dust, temperature variations
- Multi-shift operations: Equipment used 24/7 by different operators
- EU compliance: Strict CE and local safety regulations
- Cost efficiency: Need to optimize maintenance budget
The Solution
After thorough evaluation of multiple brands, Central Europe Manufacturing partnered with GMH Lift to acquire:
- 6 units of Zoomlion ZA16J Electric Articulating Boom Lifts
- Working height: 16m (52ft 6in)
- Horizontal reach: 8.5m (27ft 11in)
- Platform capacity: 230kg (507lbs)
- Zero tailswing for confined spaces
- Electric power for indoor air quality
- CE certified for EU compliance
- 4 units of Zoomlion ZS1212DC Electric Scissor Lifts
- Working height: 12m (39ft 4in)
- Platform capacity: 450kg (992lbs)
- Compact design for production floor access
- Electric power with long battery life
- 2 units of Zoomlion RT Scissor Lifts (Rough Terrain)
- Working height: 14m (45ft 11in)
- Platform capacity: 450kg (992lbs)
- Diesel power for outdoor yard work
- Four-wheel drive for uneven surfaces
Implementation
Phase 1: Safety Assessment (Week 1-2)
GMH Lift safety engineers conducted comprehensive facility audit:
- Identification of all height access requirements
- Ground condition and space constraint analysis
- Integration with existing safety systems
- Risk assessment for each application
Phase 2: Custom Safety Integration (Week 3)
Equipment customized for facility requirements:
- Integration with plant access control system
- Custom inspection checklists aligned with company safety protocols
- Polish language controls and manuals
- High-visibility markings for production floor
Phase 3: Comprehensive Training (Week 4-5)
Extensive training program for 45 operators across all shifts:
- Operator certification (24 hours per operator)
- Polish language training materials
- Shift handover procedures
- Daily inspection protocols
- Emergency response training
- Refresher training schedule established
Phase 4: Phased Rollout (Week 6-10)
Equipment deployed by production area:
- Production Hall A – Week 6-7
- Production Hall B – Week 8
- Production Hall C – Week 9
- Warehouse and outdoor areas – Week 10
Results
After 14 months of operation, Central Europe Manufacturing achieved exceptional results:
Safety Performance
- Zero recordable incidents in 14 months (ongoing streak)
- Zero near-misses related to aerial work
- 100% compliance with EU CE regulations and Polish safety laws
- 95% reduction in safety observations related to height access
- Recognized with regional safety excellence award
Productivity Gains
- 50% faster maintenance task completion
- 70% reduction in scaffolding setup time
- 45% increase in preventive maintenance frequency
- 97% equipment availability rate across 24/7 operations
Cost Savings
- €185,000 annual savings in contractor and rental costs
- 40% reduction in maintenance labor costs
- 60% lower scaffolding expenses
- ROI achieved in 5 months
Operational Improvements
- Improved production uptime with faster maintenance response
- Better equipment reliability through more frequent preventive maintenance
- Enhanced worker morale with modern, safe equipment
- Reduced contractor dependency for routine maintenance
Client Testimonial
“Safety is our top priority, and the Zoomlion equipment from GMH Lift has been instrumental in achieving our zero-accident target. The equipment is reliable, well-built, and the operators find it easy and comfortable to use. GMH Lift’s training program was excellent, and their ongoing support has been outstanding. This investment has paid for itself many times over in safety improvements alone, not to mention the cost savings.”
— EHS Director, Central Europe Manufacturing Sp. z o.o.
Key Success Factors
- Safety-first approach: Equipment selection driven by safety requirements
- Comprehensive training: All operators properly certified and confident
- Multi-shift management: Clear handover procedures and accountability
- Preventive maintenance: Scheduled servicing prevents equipment failures
- Local support: GMH Lift’s Eastern Europe network ensures rapid response
- Continuous improvement: Regular safety reviews and protocol updates
Best Practices Developed
Lessons learned from 14 months of 24/7 operations:
- Digital inspection logs accessible to all shifts
- Color-coded key system for equipment status
- Weekly safety briefings include aerial work topics
- Monthly equipment performance reviews
- Quarterly refresher training for all operators
Conclusion
This case study demonstrates that investing in quality aerial work platforms, combined with comprehensive training and strong safety culture, can achieve world-class safety performance while delivering significant operational and financial benefits. GMH Lift’s expertise in equipment selection, training, and regional support enabled Central Europe Manufacturing to achieve their zero-accident target while improving maintenance efficiency.
For manufacturing facilities in Eastern Europe, Southeast Asia, Middle East, South America, or Africa looking to improve their safety performance and operational efficiency, GMH Lift provides comprehensive solutions including equipment selection, operator training, and after-sales support.
About GMH Lift
GMH Lift is a leading exporter of aerial work platforms and construction machinery, serving customers worldwide with premium brands including Genie, JLG, Skyjack, Haulotte, Dingli, Zoomlion, and Sinoboom. Contact us today for a consultation on your specific requirements.
