Automating Six Inserts to Improve Ergonomics, Quality, and Cycle Time

Case study · Brass insert installation

By Alex Spurgeon — Published 2026-09-21

A manufacturer was installing six inserts into each plastic part by hand, one at a time, which caused operator fatigue, repetitive-stress injuries, and part-to-part variation. U.S. Heatstake built a benchtop system that installs all six inserts simultaneously in a single controlled cycle. The result: shorter cycle time, less scrap, and no repetitive manual insertion.

At a glance

Application	Six inserts installed in each plastic part
Previous process	Manual insertion, one insert at a time
Problem	Repetitive-stress injuries, operator-to-operator variation, long and inconsistent cycle time
Solution	U.S. Heatstake benchtop system installing all six inserts in one cycle
Outcome	One cycle instead of six operations, less scrap and rework, more throughput without adding labor

The challenge: six manual insertions on every part

A manufacturer had been installing six inserts into each plastic part manually, one insert at a time. The process had been used for years, but the repetitive operation was beginning to create significant ergonomic concerns, including operator fatigue and repetitive-stress injuries.

The manual process also introduced variation from operator to operator. With six separate insertion operations required for every part, cycle time was long and inconsistent, and scrap and rework were an ongoing concern.

The solution: all six inserts in a single cycle

U.S. Heatstake developed a benchtop system capable of installing all six inserts simultaneously.

Instead of an operator performing six individual insertion operations, the part is loaded into the fixture and the automated system completes all six inserts in a single controlled cycle.

Automation also provides consistent process parameters from part to part, removing much of the variation associated with manual insertion.

The results

Six inserts installed simultaneously instead of one at a time
Dramatic reduction in overall cycle time
Elimination of repetitive manual insertion
Reduced operator fatigue and ergonomic risk
Improved consistency and finished-part quality
Reduced scrap and rework
Increased throughput without adding labor

By automating all six insertion points at once, the customer was able to address an ergonomic problem while simultaneously improving productivity and quality.

Common questions

Can multiple inserts be installed in a plastic part at the same time?

Yes. In this application a U.S. Heatstake benchtop system installs six inserts simultaneously in one controlled cycle. The operator loads the part into a fixture and the system completes every insertion point at once. U.S. Heatstake benchtop presses support up to eight inserts per cycle.

How does automating insert installation reduce ergonomic risk?

It removes the repetitive motion. Instead of pressing in six inserts by hand on every part, the operator only loads and unloads the fixture. In this case that eliminated repetitive manual insertion and reduced operator fatigue and repetitive-stress risk.