Assembly Made Simple with help from Air Power, Presto, GCI, and Cleco
In this case study, Air Power builds a custom integrated system that makes Ergonomics, Safety, and Quality simple with a team effort.
Customer
This customer is a supplier in the Truck and Bus industry.
Challenge
The customer needed to outfit a new work cell assembling large metal components. First, the weight of the fully assembled sub-build components exceeded 1000 lbs. requiring a high weight capacity work table. Secondly, the height variation of the operators presented ergonomic issues from shift to shift to ensure each operator performed his necessary tasks at optimum work heights for ergonomics and safety. Thirdly, target torque for each component exceeded the safety threshold for handheld tooling, 69 ft/lbs, and 135 ft/lbs. requiring a torque management solution to be included in the overall work cell build. Lastly, the components needing to be torqued are deemed quality critical, requiring all data for the fasteners to be documented to ensure a proper build.
Air Power Solution
Air Power included the following in our solution; a 2000 lbs. capacity adjustable height pneumatic Presto lift table, a GCI torque reaction arm, and a Cleco MPro 300 controller with right angle NeoTek tool. We were able to meet the high weight by working closely with Presto directly to customize the adjustable height scissor lift table. GCI was able to build a custom torque arm to provide the needed reach and vertical travel while managing up to 240 NM of torque reaction. We were able to mount the torque arm directly to our adjustable height table, allowing the entire work station to adjust to ideal work height for any given operator. All of this wrapped around the brand new Cleco 300 controller with NeoTek right angle tool allowing for a precise fastening solution meeting and exceeding the quality critical parameters required. The Cleco 300 also allows our end-user to monitor, collect, and organize critical data to ensure they every unit out the door is a quality part.
Results
Air Power’s solution addressed all of the problems the customer faced with this assembly process. The Presto Lift table allows the operator to adjust the height of the entire system to eliminate and bending and back strain. The GCI torque arm holds and handles the Cleco right angle NeoTek tool. This eliminates any lifting and hand or wrist injury from handling a torque tool. Lastly, the Cleco mPro 300 controller gave the customer the ability to ensure perfect quality with every assembly.
Outdated impact guns causing bottleneck on the production line
Problem:
The customer presented with multiple issues caused by using outdated impact guns in their production process. 1. They were using multiple impact guns at a station with no visibility for tracking torque. 2. The impacts were hard on the operators hands as well as extremely loud. 3. They were having to change tools on the airline constantly.
Solution
After on an onsite review of their unique production process, examining the enhanced technology available in newer impact guns, the best solution was to implement Panasonic Transducerized AccuPulse Tools.
Results
The operators are now able to pick up a socket which will automatically change to the desired torque for the correct valve. The tool is fast, accurate and much more ergonomic than the pneumatic impacts they were using. They plan to collect data in the future and with the controllers talking to their MES system, they will now be able to do that. Team Air Power was able to create a happy customer with another specialized Manufacturing Solution.
A new machine requires a custom crane and hoist design..no problem
Problem:
The client, a local granite countertop supplier, was purchasing a new machine to custom cut their client’s countertops. Their existing workstation crane and hoist system didn’t allow the flexibility they needed to maneuver the granite into the proper position.
Solution
After on an onsite review, it became clear that a custom designed crane and hoist system was needed for the project. Account Manager Justin Kuhn and Application Specialist Chris Nelson were able to custom design a 2 ton Gorbel crane and 1 ton Harrington Hoist system that allowed the power and flexibility the client needed.
Results
The Air Power solution is working perfectly and this will likely be the last crane the customer will ever need. The added bonus was an annual maintenance plan for all of their existing cranes and hoists. The ability of our team to not only immediately identify the issues, but to also have the technical skill to design a customized system leads to the perfect Manufacturing Solution.
Once again the tremendous knowledge and experience of our Account Managers and Application Specialists not only solves the issue at hand, but creates a long term customer.
Powder booth Airflow issues solved by an Air Power Dynamic Duo
Problem:
The client, a local manufacturer, was having air flow issues within it’s paint operation. This was causing major dust/powder buildup in the nearby areas of the plant. Not only this, but the inefficiency of the airflow was hampering overall plant performance.
Solution
After on onsite review with the customer, Chris Case (Account Manager) and Travis Stirewalt (Technical Specialist) were able to determine that the 2nd and 3rd stages were horribly neglected. In addition, we pointed out that although airflow with no filters and clean filters was excellent, the airflow with the clogged stage 2 and 3 were causing the issues. We installed the Kemwove filters during a one day trial and testing period of the filter process. Two weeks later, we revisited the plant to check on the filters and then again a couple of weeks after that. The customer had moved into some of their old first stage inventory (paint pockets) but had left our 2nd and 3rd stages alone as requested. The 2nd stage filters were absolutely full and had spared the bulk of powder capture leaving the 3rd stage pocket filters in great shape.
Results
With the collected data over the test and review period, we were able to provide a concise filter plan and maintenance schedule for monthly, quarterly and annual review. For this customer – better air flow, improved plant performance, and a reduction of annual filter costs!
A client needed faster color changes…Air Power and Gema to the rescue
Problem:
Our clients operators were already using Gema box units for their non-recovery powder booths. While the units worked wonderfully these booths were connected and would be considered opposing. Each time they need to change color the operator must lift a 50lb box on and off the vibrating platform. This was a huge ergonomic issue for everyone involved.
Solution
After reviewing the setup and assessing the clients daily needs it was obvious that a Gema 8 color quick change package would allow for faster color changes, reduced material handling of the boxes of powder and would better prepare hard to fluidize powders in hoppers verses vibrating box units.
Results
Any time you can make a client’s operation more efficient, save wear and tear on their operators and show the how quickly the ROI would balance out….they are going to be happy. You almost always have to spend money to save money so having a team that understands your operation and knows all the available options to increase productivity is vital. Team Air Power got the job done once again.
As temperatures begin to get hotter, viscosity is very much at play when picking the proper pump.
Problem:
When specifying the proper pump for any fluid application understanding the properties of the fluid to be handled is of the upmost importance.
Viscosity…. is one of, if not the most important variable when determining the proper specification of a diaphragm pump (or any pump) and associated flow rates. The viscosity of many materials fluctuate as ambient temperature’s change through the seasons and as plant conditions change month to month, so understanding the effect viscosity has on sizing pumps is important.
Solution
All AODD pump ratings are with water at the pump outlet. For example, a Graco 1050 pump is a 1″ ported pump rated at 50 gallons per minute (water at the pump outlet). When looking to specify the above example pump, three things must be further evaluated to insure proper performance/specification – Viscosity (will alter flow rate), available air pressure at the pump, pipe or hose size (at pump outlet all the way to the point of discharge). Once you have determined these variables you can properly select the perfect pump for your unique application.
Results
Getting the right pump will make a world of difference in the efficiency of your set-up. Not only will your flow rates remain stable throughout the year, but downtime will be reduced and the life of your pump will be extended.
Graco Endura-Flo pump solves multiple issues for large paint booth
Problem:
The customer came to Air Power wanting to upgrade their pump package that supplies material from their paint kitchen to two applicators on each end of their booth. The booth runs 60’ long, with a width of 20’ and would be used to touch up dump truck beds. After running a pressure drop calculation we determined that the material could fall out of solution if there were a day or 2 that no spraying was needed.
Air Power Solution
After reviewing the application with the customer, Air Power proposed using a 3:1 Graco Endura-Flo pump. This option allows for the 3x the pressure, which was more than enough to overcome any pressure loss during the materials travel, as well as, has a much larger fluid section requiring less wear and tear on the pump while in operation. Since this is strictly a touch up process and not guaranteed to be an everyday event, we also recirculated the fluid lines to prevent any material from falling out of solution.
Results
This solution provided more than enough pressure to power the required spraying. Additionally, if there’s an occurrence where the system isn’t used for several days, the customer only has to run the pump a few minutes before spraying to move the stagnant material back within the agitated drum requiring no waste or quality concerns.
The Air Power solution solved the pressure problem, the potential solution issues, and provided a much larger fluid section to prevent wear and tear.
Intelligent Multi Spindles Increase Production and Quality
Problem:
A local axle manufacturer has had ongoing issues with accurate torqueing of axle shaft bolts. The bolts are inaccurately torqued with pneumatic pulse tools or missed altogether by the operators as they are in 8 lug and 12 lug patterns and require many accurate rundowns to produce a quality part.
Air Power Solution
Apex Tool Group intelligent 4 spindle multi-spindles with torque management arms eliminate both inaccurate torques along with potential mishits of fasteners. The 4 spindles will be adjustable to hit both patterns, highly accurate within a few percent of the targeted torque, and have rotational transducers that will tell us which fasteners have been hit and eliminate missed fasteners and re-hits by the operators.
Results
This solution will decrease the amount of manual operator input of fastener tightening thus speeding up the manufacturing process, as well as, eliminate re-hits and missed fasteners by the operators. This system will collect data and communicate with their existing MES system to confirm the accurate torque of each set of axle bolts, providing data points and a birth certificate of a successful assembly. This will have a profound effect on both the quality of the parts produced as well as the speed at which they are produced. One ergonomic bonus – the system will remove the operator from handling the existing large pneumatic pulse tools manually creating for a safer and more sustainable work environment.
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