Ingersoll Rand – Makes it Easy

One of the main causes of injury in a manufacturing facility is due to lifting heavy objects. In this case study, Air Power helps a customer eliminate the risk of injury with an Ingersoll Rand custom monorail lifting system.

 

Challenge

 

A local machinery manufacturer has had issues finding a suitable solution to include as part of their OEM machinery builds. They had a history of using electrical hoists and I beam trolleys which have not been well received by their end-users. The previous offerings by others were hard to maneuver and difficult to position the load for final placement.

 

Air Power Solution

 

Air Power proposed an Ingersoll Rand Zimmerman rail system, which are easily adaptable, cost-effective and easy to use. We designed a system for them that included 4 individual monorails with rigid mount hanger kits to increase clearance and ZAW air balancers with pendant controls for load lifting and proper part positioning.  The solution allows each of the 4 sides of their machine to be covered from end to end.

 

Results

 

The proposed solution provided the necessary benefits including:

  1. The ZRA1 monorails utilized minimum push/pull forces, allowing ergonomics on the operator and ease of use.
  2. For future integrations, the individual monorails provide an easily adaptable solution, should the OEM design change over time.
  3. The aluminum profile ZRA1 provided a reduction in solution weight.
  4. The ZAW air balancers allow the end-user to position the load close to its final destination then use the “float” of the balancer for final (and exact) placement of the part; further enhancing the user experience.

Assemble Faster with IR DC Tools

The assembly process in manufacturing plants typically is the largest drain on human labor resources.  Anything that can be done to speed up that assembly process is critical.  Especially, if it creates a reduction of labor and increased throughput, and increased quality in the final product.

 

Customer

A Global supplier of compression molded plastic parts to tier 1 automotive, Heavy Truck and bus, Heavy equipment, marine, reactional vehicle manufacturers.

 

Challenge

This company has 3 work cells installing multiple fasteners into door panels for Tier 1 automotive.  They were using two tools per station (One DC, One pneumatic) and manually inserting and driving to torque 3 fasteners.  This resulted in 3, 8-hour shifts of assembly 5-6 days a week to meet production demands.  With this process, torque values were not being collected and there was no assurance of quality.  Resulting in inconsistent quality, frequent rework, and often rejected batches of parts.

 

Air Power’s Solution

Air Power, Inc. in Partnership with Design Tool Inc. (DTI) proposed a solution utilizing both Ingersoll Rand DC Tools and DTI screw feeders.  This would reduce Takt time thanks to the DTI screw feeders and assure consistent torque values and alert if there was an issue from bad fasteners,cross-threading, etc.

 

DC Tool System with Screw feeder

Result

Utilizing the DC tools along with the DTI Screw Feeders we were able to dramatically reduce takt time, increase quality, and dramatically reduce the amount of labor needed to meet production demands.

  • Labor was reduced from (3) 8-hour shifts running 5-6 days a week to (1) shift 4 days a week.
  • First Pass quality increased by 80%
  • Rework is almost non-existent because any defects in fasteners or torque are corrected or captured in the work cell instead of at the end-user or in the quality department.

 

 

 

Cleco CellTek Launch

Cleco’s advanced tool and assembly solutions enhance user experience and increase productivity, providing powerful results for your company. They leverage new technology to increase tool accuracy, traceability, ergonomics, and safety. As a leading tool manufacturer, Cleco offers trusted tool solutions across numerous industries. Whether your company constructs high-tech automobiles, assembles planes for leading aviation projects, produces appliances, or builds earthmoving equipment, you can count on Cleco Production Tools for intelligent assemblies and world-class tools.

Cleco is very excited to present the future of connectivity, CellTek, part of our growing line-up of cordless electric tightening tools. Check out the CellTek experience!

 

 

Cleco CellTek Brochure

 

Cleco CellTek Brochure

 

Cleco CellTek Brochure

 

Cleco CellTek Brochure 4

 

 

 

Want to learn more about Cleco Production Tools from Air Power Manufacturing Solutions?

Click this link to view and/or download a copy of the Cleco Production Tools Catalog

 

2020 REWIND

12 Days of Christmas Giveaway

12 Days of Christmas Giveaway

 

Air Power would like to announce the 12 Days of Christmas Giveaway! Starting today we are giving all our followers an opportunity to participate to win some AMAZING prizes! Over the next 12 Days we will post an image of our awesome prizes and ask you to Like and Share the post to participate. You will have 24 hours to engage with this post to be included in the drawing. The rules of the giveaway are listed below:

  • Participants must Follow Air Power on either LinkedIn, Facebook, Twitter, Instagram, or Subscribe on YouTube to be entered in the drawing
  • You must Like this post for 1 entry and/or Share the post for 2 entries
  • Participate between Dec 13th – Dec 25th
  • All Participants must be 18 years or older
  • Air Power Employees or Air Power Vendor Suppliers are not eligible for prizes.

We will announce the winners every day on all our social media channels. Connect with us to stay updated!


 

And the Winners Are . . .

 

Day 1- Joe Makr

Day 2- Jack White

Day 3- Steve Grubb

Day 4- Robert Hooven

Day 5- Tim Lintz

Day 6- Jon Jay

Day 7- Gary Turner

Day 8- Christopher Sweeps

Day 9- Johannah Brookwell

Day 10- Mark Foster

Day 11- Laura Kornak

Day 12- Ashley Shelton

 

Cleco CellTek Truck Tour Visits High Point

 

We’d like to Thank Cleco Production Tools for visiting our High Point Branch this past week! Our team had a blast learning about the latest innovations in assembly tools from Cleco.

 

 

Feel the Future of Connectivity: Designed to enable the Smart Factory of Tomorrow, Cleco introduces the most advanced cordless nutrunner, CellTek. CellTek Cordless Assembly Tools bring superior connectivity, with the most reliable real-time synchronization with manufacturing and engineering systems. Designed to ensure safety-critical assembly with best-in-class accuracy, CellTek is also the fastest cordless assembly tools in its class.

 

 

 

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