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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.

 

 

 

Schmalz Makes Lifting Easy

Manufacturing commonly requires operators to lift and move heavy materials, which can lead to injury and fatigue. This material handling solution makes lifting a breeze.

Customer

A leading US Electronics Recycling Company.

 

Challenge

This customer wanted to reduce the possibility of injuries from the amount of lifting their operators were exposed to. This problem was leading to higher turnover in specific areas due to common complaints of lifting parts that were upwards of 120 lbs! Thus reducing the rate of production and declining morale throughout the production floor due to manual lifting.

 

Air Power Solution

The Schmalz JumboFlex 50 was able to lift the customers’ desired weights of 40-120 lbs and capturing their desired throughput goal of 60-70%. This piece of equipment utilizes a vacuum suction pump that relieves the weight of the piece you’re picking up and relieving the amount of strain on the operator’s backs. Pairing the JumboFlex with Schmalz’ Column Mounted Jib Crane, we are able to reach out 10ft and have 270 degrees of full motion!

 

Results

This material handling solution completely eliminated the customers’ problem. The Schmalz JumboFlex 50 eliminated the risk of injury for operators. This allows them to work faster, increases the rate of production, and reduces fatigue from constantly lifting heavy materials. The Section Manager stated, ” It’s not about the speed we’re able to go at, what this piece of equipment has done for us is, improve employee morale and reduce turnover now that they don’t have to lift heavy stuff all day long.”

 

 

Ingersoll Rand In-Line Handle Air Balancer Control Kit

 

Ingersoll Rand In-Line Handle Air Balancer Control Kit

 

Designed for precise pick & place applications, the Ingersoll Rand In-Line Air Balancer Control Kit can integrate with all of Ingersoll Rand’s existing single rope basic unit air balancers.

– Compatible with 150, 200, 350, & 500 lb. capacity air balancers.
– Adjustable lifting and lowering speed based on pressure applied to up and down movements.
– Ideal for repetitive pick and place lifting applications.
– “Float” range allows for precise placement.

 

Contact Air Power today to get a live demonstration!

 

Ingersoll Rand Advanced Tightening System

Air Power, Inc. presents a demonstration of Ingersoll Rand’s Advanced Tightening System by Kyle Crawford

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