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.

Base In Place.

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.

Added Protection.

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).

The Fastener Installed.

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!

Pyramid Complete.

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!