Mountz Torque was approached by a loyal Aerospace client seeking to enhance their productivity. The aerospace company employed light assembly electric torque screwdrivers in its assembly operation to construct power modules situated beneath the middle seat in each plane row, facilitating passenger device charging. With 64 boxes needed per aircraft, retrofitting an entire fleet demanded swift delivery of substantial cage volumes. Simultaneously, maintaining quality was paramount, with cross-threading posing a genuine risk. Any box failure could ground an aircraft, underscoring the necessity of prioritizing assembly product quality.
CASE STUDY AUTOMOTIVE MANUFACTURING
IMPLEMENTING ERROR- PROOFING TOOLS FOR PROCESS OPTIMIZATION HVAC Manufacturer for the Vehicle Industry Bergstrom is one of the world’s leading manufacturers of climate control solutions for the commercial vehicle industry. The company designs and manufactures cab climate systems for various automotive vehicles, commercial trucks, off-highway machines, military vehicles, and other specialty vehicles. As a technology leader in thermal management, Bergstrom deploys manufacturing methodologies, tools, and techniques to deliver reliable climate systems that stand up to demanding environments. Producing high-quality products with an optimized total acquisition cost is of critical importance to their customers. At their United Kingdom facility in Whales, an engineering team sought a tooling solution to resolve an ongoing risk with some fastening applications. The project is for AC units that they produce for Volvo automobiles. Due to visiting restrictions, the engineering team couldn’t have an onsite product demonstration. Mountz provided an alternative solution by offering them a virtual product demonstration via Zoom.
AT A GLANCE
CHALLENGES • Issues with quality assurance due to missing screws impacting productivity delays and rework costs • Ensuring fasteners are tightening in proper sequence • Cross threading issues causing defective products SOLUTIONS • Screw counting process eliminates the risk of cross-threading, omissions, unfinished rundowns • Fastening automation workflow process preventing operator errors • Soft-start feature reducing the risk of cross-threading RESULTS • Enhanced quality and reduced scrap rates • Optimized manufacturing process and removed human error risk • Automated data capture throughout assembly ensuring conformity with quality standards
CASE STUDY HVAC MANUFACTURER FOR THE VEHICLE INDUSTRY
Challenges They were interested in a power tool to enhance process reliability and production efficiency to prevent product defects and reduce scrap rates. The engineering team was looking for a torque control system with error-proofing capabilities and the ability to program multiple torque settings. The automotive AC product required screws tightened in a fastening sequence and three different torque settings ( 2 N.m, 3.6 N.m, and 4.2 N.m). The fastening process also needed an electric screwdriver with a programmable “soft start” setting. This feature would let the power tool start slower, allowing a fastener to engage the threading properly and eliminate the risk of cross-threading events occurring. The power tool’s speed would ramp up automatically afterward. With ongoing issues of a product getting rejected because of incomplete fastening events and missing screws during the QA review stage, the engineering team needed an error-proofing tool that provided real-time monitoring of the assembly process and a method for recording and storing the torque and fastening data. Solutions To ensure the correct torque with every fastener tightened in the proper sequence, Mountz provided a smart electric screwdriver solution that safeguards against fastening failures. The ECT intelligent screwdriver system is a transducerized tool that features a built-in sensor that continually measures torque in real-time and feeds data back into the system. The tool’s I/O interface enables them to integrate the system’s digital signal output for real-time process monitoring and data collection. They could program the three preset torque settings with a single tooling system instead of using multiple electric screwdrivers to complete the different tightening events. Grouping the fastening sequence, soft-start settings, and the three torque settings into one multi-sequence event allows them to achieve multiple fastening tasks with a single automated fastening workflow. Manufacturing the product with consistent quality requires equipment to execute production tasks with high precision and repeatability. The screwdriver system provides error-proofing capabilities that track each screw the tools fasten. They could program
The error-proofing system eliminates manufacturing risks and prevents fastening errors like cross-threading, omissions, unfinished rundowns, stripped screws, and cam-outs.
CASE STUDY HVAC MANUFACTURER FOR THE VEHICLE INDUSTRY
the ECT tool not to clear an assembly until all the fastening events are completed. If a fastening error occurs, the torque control system will detect it and flag it. Adding an EZ-Glider torque arm as part of the solution package provides additional benefits as it prevents the screwdriver from accidentally being dropped on the floor or the product. The ergonomic solution prevents employee injuries and reduces operator fatigue. Results Error-proofing the assembly process improves their quality by reducing the number of defective products rejected during the quality review stage and eliminating the risk of product failures in the field. The poka-yoke system is providing real-time monitoring and error detection. They can streamline the manufacturing process and remove human error risks by grouping multiple repetitive tasks into a single fastening workflow. The automation process enables Bergstrom a manufacturing method to achieve and maintain process uniformity. In addition to preventing errors in assembly, the new solution also collects production data on the line, allowing them to generate a detailed production record of every product they’ve assembled. The ergonomic arm is improving employee safety as it absorbs torque reaction and preventing repetitive stress injuries.
APPLY THESE IDEAS • Implement a fastening automation workflow process when there is a repetitive series of tightening tasks • For enhanced quality control, add a screw counting process to eliminate costly screw-fastening errors • Achieve multiple fastening tasks with one tooling system • Deploy screwdriver system provides error-proofing capabilities that track each screw the tools fasten. • To prevent cross-threading, consider a tool with soft start capabilities
Contact us today to find out how Mountz can help your company implement error-proofing and workflow automation equipment for executing production tasks with high precision and repeatability.
ABOUT MOUNTZ Mountz, The Torque Tool Specialists ® , has been a leader in the torque tool industry for more than 55 years. Engineered in the Silicon Valley and serving the globe, Mountz focuses on delivering high-quality torque products, services, and solutions to ensure customers can always proceed with confidence. We are committed to forging a safer world through precision and accuracy, and by innovating every day.
SILICON VALLEY HEADQUARTERS AND SERVICE CENTER 1080 N. 11th St., San Jose, CA 95112 408-292-2214 / M–F 6am–5pm PST ALABAMA DISTRIBUTION AND SERVICE CENTER 19051 Underwood Road, Foley, AL 36535
INTERNATIONAL For inquiries outside of the USA, Canada, and Mexico, please contact: international@mountztorque.com Phone: +44 1428 741756
mountztorque.com
Copyright © 2021 Mountz Inc. All Rights Reserved. V1/090721
Page 1 Page 2 Page 3Made with FlippingBook Annual report maker