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Learn how error-proofing techniques and advanced torque systems can minimize mistakes in assembly, reduce costs, and boost profits for your customers. Discover the different levels of error-proofing in torque control and how they can benefit your customers' processes. Find out about torque tool calibration, interim tests, standard torque tools, and advanced torque systems that significantly reduce operator errors. Joint auditing and process cost reduction strategies also play key roles in enhancing profitability. By implementing error-proofing solutions, you can help your customers save money and increase efficiency in their assembly operations.
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Sturtevant RichmontAdvanced Torque Systems Error proofing your customers assembly process – for mutual profit! Or, “No more misteaks!” June 21, 2007
How many times . . . • Has your customer said: • “We missed a fastener.” • “It’s loose!” • “We overtightened it.” • “Which fastener did I leave off at?”
These statements are a sales opportunity. • Every time this happens your customer lost money. • The customer will have documented these and their costs. • Eliminating them provides a sale and a documented savings!
What they need is called“Error-Proofing”. • Error-Proofing is the application of designs, products and procedures that reduce the probability of error occurrence. • Error-Proofing applies to simple and complex processes at many levels.
Error-Proofing & Torque Control • When the concepts of Error-Proofing are applied to torque control in assembly operations, there are several levels of application. • The more error-proof the process, the more likely the process will produce high-quality products reliably. AKA: “No more misteaks!”
Error-Proofing Levels in Assembly Torque Control Building the pyramid!
Periodic Torque Tool Calibration – The Base • Inaccurate tools invite error. • This means that regardless of the torque tools used, periodic calibration is essential to an error-proof process.
Interim Torque Tool Tests –A Strong Step Up. • Tools can and do go out between calibrations. • Interim tests, such as at the start of each shift, reduce the probability of this error occurring and save money.
Standard Torque Tools –The Most Rudimentary Method • Standard torque tools afford some process protection. • Human error in their application remains possible.
Advanced Torque Systems –A BIG Step Up! • Advanced torque systems address operator error directly, dramatically reducing the chance of affecting the process and product.
Advanced Torque Systems –Two Different Approaches • Advanced torque systems use either attribute (Good/Bad) or variable (numeric) data to provide immediate feedback to the operator and the line. • Either approach can provide a large reduction in errors.
Advanced Torque Systems –Attribute Approach • Attribute systems (Accept/Reject) use communicating torque wrenches and base units to provide feedback to the operator and the line.
Advanced Torque Systems –Attribute Approach 2 • These systems communicate directly with the line via PLC communications. • This integrates the error-proofing improvement with efficient line control.
Advanced Torque Systems –Variable Data Approach • These systems give digital numeric torque data on each use to other processors to provide control. • They also provide absolute proof of conformance.
Advanced Torque Systems –Variable Data Approach 2 • These systems can be applied as near real time systems (1/2 second delay) or batch systems (collect data, upload later).
Joint Auditing –The Last Step • Joint auditing is simply performing periodic checks on the effectiveness of the process by testing the residual torque on the fasteners after assembly.
Joint Auditing –Part 2 • The data is collected as either attribute data or variable data. • The amount of auditing needed depends upon the process and tools used in torque application!
Process Costs –The Real Improvement Driver • Bottom line - the ultimate job of the process is to make a profit for the company. • The lower the ongoing process costs, the more money the customer makes. • Error-proofing lowers your customers ongoing costs and increases his profit - making you a most valuable distributor!
Process Costs –Part 2 • Ongoing costs are a greater determining factor in profitability than equipment acquisition costs. • This is why many firms spend $15K+ for an advanced torque system instead of $300 for a standard tool.
Process Costs –Part 3 • When rework, repair, and warranty costs are reduced, the payback time for an advanced system is short. • Since advanced systems allow less-frequent joint audits, the payback time becomes even shorter.
Process Cost Reduction –The Key to More Sales! • Every engineer and every department manager wants to reduce their costs. • If you look at their processes from a cost perspective, you will find where the opportunities lie.
Summary • Your customers need to reduce their ongoing costs to improve their profitability. • Error-proofing the assembly process dramatically reduces their ongoing costs. • As an S/R ABD Distributor you have available the products that can make a large reduction in your customers process costs via error-proofing. • Applying a cost perspective in your analysis of the customers needs will increase your sales!
