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.
A Global supplier of compression molded plastic parts to tier 1 automotive, Heavy Truck and bus, Heavy equipment, marine, reactional vehicle manufacturers.
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.
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.
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More about: Southworth Products
Overspray in industrial finishing applications is one of the most common causes of parts being rejected by quality control inspections. This can result in constant costly reworks and low-quality finish on parts. In this case study, Air Power proposes a solution that completely eliminates overspray for this customer.
Manufacturer of plumbing and water-related fittings and valves
This customer was experiencing paint buildup on their booth due to overspray. This was caused by inefficient airflow through the booth. This customer was using an old baffle style booth that uses offset layers of metal to catch the initial overspray and then redirects the overspray into the second layer of filters. As a second layer of filtration, the customer used Styrofoam baffle filters that allowed a high volume of bypass of a mixture of tacky and dry overspray. This type of baffle filter works better with wet paint overspray.
Without proper airflow collecting the overspray in the booth, this customer experienced a higher number of rejected parts, a lower quality finish on products, and paint buildup on their spray booth and surrounding areas.
Air Power Solution
Air Power proposed a solution that updated the filtration system to a more efficient style. This solution included completely removing the metal vertical baffles that were the first stage of filtration. The second stage Styrofoam baffle filters were then removed and the 20×20 grid was scraped clean of all the overspray buildup. Then we installed Kem-Wove P3 20×20 panel filters in the second stage, installed snapper bars on the front of the filter wall, and added RP 3252 paper/poly blankets (RTT Engineered Solutions / Col-Met) as the first stage of filtration to improve overspray capture and airflow.
This customer was amazed by the change in airflow and overspray capture in their spray booth. This new filtration system collected all the overspray in the booth and allowed nothing to bypass for the first time. These changes improved the painting conditions for operators in the booth, allowing for a higher quality finish on products. This customer is currently in the testing stage with this system to determine the length of life for one layer of filtration to ensure this system is cost-efficient and establish best practices for their finishing operation.
Air Power has been featured by Finishing and Coating in a full-length article that highlights Air Power’s recent growth with the Zenmar acquisition. The article also talks about Air Power’s rich history in the manufacturing industry and the services we provide to the manufacturing community. We’d like to Thank Tim Pennington and the team at Finishing & Coating for recognizing our impact in the manufacturing community.