In this case study, Air Power builds a custom integrated system that makes Ergonomics, Safety, and Quality simple with a team effort.
This customer is a supplier in the Truck and Bus industry.
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.
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.
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!
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
Our 2018/19 National Sales Meeting – “No Fear, No Limits, No Excuses” surrounded the removal of roadblocks. We spent 2019 addressing these roadblocks through sales training, marketing initiatives, and more opportunities to meet vendors. Air Power has benefited from this endeavor and our organization continues to see growth. This year our Accelerate theme represents our initiative to Accelerate into 2020 without fear and the tools necessary to overcome any roadblocks.
We kicked off our Accelerate 2020 Sales Meeting at our new branch location in Greenville, SC. Our team arrived around 1pm with time to tour the new facility while helping themselves to drinks and light hors d’oeuvres. The team also participated in a friendly tire changing competition with the Ingersoll Rand replica Pit Stop, designed to mimic the real nascar pitstop experience. With the shortest time of 15 seconds, Rodney Benfield was announced as the winner!
Air Power President Dan Senff kicked off the meeting by welcoming our team to Greenville. 2019 was a great year for Air Power and we were excited to share our successes with our hard working team. We spent the evening enjoying the view from Up on the Roof Bar, where Air Power hosted a happy hour event. Our team along with our Top 5 Vendor sponsors enjoyed the beautiful Downtown Greenville view while we celebrated the end of the year.
Thursday began with breakfast in the Embassy Suites Downtown Riverplace. Our group moved into meeting space and we spent a few hours announcing some exciting process changes rolling out in 2020. Air Power is dedicated to continuous improvement to better serve not only our customers, but also our team members. At 10am, we kicked off the 2020 Product Training portion of our meeting. We gave each of our Top 5 Vendor Sponsors (Carlisle Fluid Technologies, Cleco Production Tools, Graco, Gema, and Ingersoll Rand) time with our team to focus on their 2020 initiatives. We find that when we focus on our goals as a team, it is impossible to fail.
After a day of getting our team revved up for 2020, we sent them to go get dressed up for our Banquet. The Accelerate 2020 Banquet and Awards Ceremony started with a Happy Hour in the foyer. Our team along with their spouses enjoyed mingling with our vendor sponsors. We enjoyed an amazing meal catered by Ruth’s Chris catering. As we wrapped up dinner, the Awards Ceremony began.
Our Big Winners of the night included:
2019 Filter Awards
Colmet (RP Filters)
1st Place: Austin Lambright
2nd Place: Len Morrison
3rd Place: Randy Pennington
Col-met (Sheet Metal) Award
1st Place: Randy Pennington
2nd Place: Shaun Patterson
3rd Place: Paul Kelly
Filter Guru Award
Customer Service Representative Awards
Most Line Items Quoted – Ricky Graves
Most quotes – Ricky Graves
Most Line items Booked/Ordered – Ricky Graves
Most Orders – Ricky Graves
Most Calls Taken – Todd Putman
Coat (FIT) Award
Assemble and Move (AFT) Award
Assemble and Move (TAS) Award
Specialist of the Year
Branch of the Year
Raleigh, NC Branch
Wayne Cassidy – Branch Manager
Account Manager of the Year
Steve Thomas – 15 Year at Air Power (42 years in the Industry)
Ronnie Lowe – 43 years at Air Power
Robin Eanes – 46 years at Air Power
We spent Friday celebrating 2019 at Speed Factory Indoor Karting. We’d like to thank Carlisle Fluid Technologies for setting up their virtual spray painting simulator. Our team had a great time competing for the best Spray Finishing score. Everyone participated in the GO-Kart race and we spent the morning finding out, who is the fastest at Air Power. Our First Place prize went to Gary Lee! Second place went to Josh Strausbaugh and our Third Place went to Matthew Graham. We’d like to thank everybody for participating in the race!
As the manufacture sector continues to change we understand the tedious task of staying current on the most cutting edge tooling technology. So, allow us to “Drive New Technology” to your facility for hands on application demonstrations, accurate torque programming, and ergonomic optimization. Whether this is for a single application demo, in which an Air Power Account Manager loads up the appropriate equipment within their vehicle and brings onsite, or a much larger venture, where Air Power in partnership with a manufacture partner bring in dedicated personal for the day, our goal is to continually be a resource and “drive new technology”. A few notable campaigns below in which Air Power, in partnership with our vendor partners, drove new technology to the customer for the most optimal customer experience.
Completing over 35 stops within the Southeast, the Cell Tour proved to be a huge success for both Air Power and Cleco. The CellTour showcased Cleco’s innovation in reinventing cordless through a unique, dynamic, and fun mobile experience. When driving this new technology, customers were able to perform hands on testing through interactive demonstrations and joint simulations. The new CellCore Cordless Assembly platform – Easy to Handle. Hard to Break. – consists of smart, durable, and ergonomically designed battery operated transducerized tools. The lightweight ergonomic design reduces operator fatigue and the large user interface makes it very quick and easy to program. The CellTour highlighted the CellCore product, as well as, provided an additional sampling of APEX’s assembly fabrication tool product solutions.
Graco – Pumps and Process
Graco’s Pump and Process trailer has made numerous stops within the southeast; including our most recent location in Salem, Va. This valuable tool is packed with operational diaphragm, piston, peristaltic, and ram pumps ready for any and all to be trained. Rob Woodward, of Graco, does an excellent job showcasing the products housed within the traveling trailer, highlighting New Graco offerings, including the Husky Electric Diaphragm Pump platform. These pumps have the advantages of double diaphragm pumps (self-priming, running dry, and stalling under pressure) with the efficiency of an electric drive (up to five times more efficient than pneumatic diaphragm pumps).
If you grind, sand, or polish, then experiencing the Dynabrade Difference during an onsite Dyna-Day is a must. Dynabrade has earned a reputation for excellence and is a leader in innovation design and manufacturing of pneumatic abrasive power tools. The fully outfitted Dyna-Van showcases Dynabrade’s commitment highlighting all the made in America tool manufacture has to offer. Whether you would prefer a parking lot trade show style setup or in plant experience, Dynabrade is flexible in catering to the user experience.
Air Power and Dynabrade are currently on a Dyna-Day roadshow within North Carolina, South Carolina, and Virginia, so far completing twelve (12) events with plenty of excitement for additional locations. A highlight of the event is being able to put the tools to use, including the new Dynorbital Extreme, known for its extreme power, extreme comfort, and extreme performance, this newly released model random orbital sander has been a show stopper.
Ingersoll Rand QX – The Future is Real
Ingersoll Rands “The Future is Here. The Future is Now. The Future is Real” roadshow allowed for the education and utilization of the QX Series platform of assembly tools. This tour highlighted the benefits of the QX platform, showcasing next generation functionality; which was evident within the hands on demonstrations that could be performed on the active stations within the truck. The complete line of QX tools feature: QXN, QXC, QXX, QXM, and the most recent QX+ETS models in both the pistol and right angle orientations. This robust tooling platform can handle any torque with pistol and right angle orientations up to 2,000NM. The New QX +ETS models feature an ergonomically enhanced motor algorithm for a significant reduction in the average force experienced by an operator during the tightening process.
Within all of our assemble, move, and coat technologies; Air Power prides itself on our ability to drive these new technologies to your facility. Not all technologies we drive to your facility, have to be as elaborate as the programs highlighted above.
Our Account Managers – Drive New Technology – every day.
Give Air Power a Call Today!