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

 

FlexArm Torque Arms with Cleco Tools

 

 Air Power Application Specialist Jerome Wood along with FlexArm Regional Sales Manager Tyler Albert showcase how FlexArm torque reaction arms and custom tool mounts work flawlessly with Cleco® tools to create simple ergonomic solutions for any workspace. Featured in this demo are the Cleco® NeoTek™ 30 Series right-angle tool and pistol grip, DOGA DMFi telescoping arms, and linear and articulating torque reaction arms.

 

 

Lobster ARF-700 Rivet Presenter

 

 

This is a Lobster R1A1 pneumatic rivet gun coupled with an ARF-700 Rivet Presenter. Allows for speed and efficiency when completing high volume manual riveting. Stocked, sold and serviced by the professional staff at Air Power, the brand expands an already deep offering of assembly tool solutions. Air Power is proud to be an authorized Lobster Rivet Tools Distributor and highly recommend them to our customers.

Learn More About Lobster Rivet Tools

Learn More from Air Power

Assembly Made Simple

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.

 

Assembly

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.

 

 

Ingersoll Rand Controller paired with FlexArm

 

Air Power Technical Specialist James Stanley demonstrates the capabilities of an Ingersoll Rand InsightQC Controller paired with a FlexArm Smart Arm with DOGA DPC Touchscreen allowing the operator to enter sequence patterns quickly and efficiently. Visit us at airpower-usa.com or call us at 1(800) 334-1001 to hear more about this system!

Product Demonstrations

Check out the latest updates at Air Power!

Product Demonstrations

Air Power Manufacturing Solutions is making efforts to be sure that we can continue to effectively support the manufacturing community during this time. We love to be able to visit customers on-site and demonstrate how the products we sell can improve manufacturing processes, but there are a variety of other ways we can show you the latest technologies. Follow the link below to read about the ways Air Power can help you improve your manufacturing process!

 

 

pRODUCT dEMONSTRATIONS

 

Ingersoll Rand QCX Controller with remote access

 

 

 

Air Power Application Specialist Jerome Wood and Technical Specialist James Stanley show the remote access capabilities of our Ingersoll Rand QCX Controller in the lab. An Ingersoll Rand QX Pistol coupled with an ETA Inline Positioning Arm paired to the Ingersoll Rand QCX Controller with remote access will allow work from home opportunity. Engineer, operator, and Air Power technical assistance on Go To Meeting are able to troubleshoot, debug and live update the system. Technology 4.0.

If you have any questions regarding remote access or would like to learn more about this technology, schedule a virtual demo today.

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New Ingersoll Rand INSIGHT Controller

Introducing the INSIGHTqcx Controller

 

Ingersoll Rand has released the INSIGHTqcx Cordless Controller for critical assembly applications in manufacturing. THe INSIGHTqcx helps manufacturers who require advanced fastening strategies, such as those in automotive, aerospace and heavy equipment, easily take control of their assembly processes.

INSIGHTqcx integrates with the wireless Ingersoll Rand QX Series precision fastening tools. The Controller can also be used to program Ingersoll Rand QXC and QXN nonwireless tools via USB cable and serves as a convenient tool programming station so that operators don’t need to take the tool to an offline laptop for programming.

Additional features include:

  • Intuitive, touch-screen programming and ready-to-use communication protocols
  • Storage for 50,000 records of cycle data and 50,000 tightening traces onboard the device
  • It is adjustable to meet any tightening control requirements

 

INSIGHTqcx Controller

 

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