This case study was presented by Baltimore Key Account Manager Lorne Rickert.
A counterweight was attached to a turntable before the Hydraulic Motor which “keys” the turntable to the frame, located underneath. The counterweight caused the turntable to rotate until it was so far off balance that the Turntable with Counterweight fell off the Frame, coming to a rest about 2’ from a Team Member! This posed a significant safety hazard, as well as, assembly frustration to the onsite engineering team.
Air Power Solution
Air Power utilized an Ingersoll Rand QX Power Tool and Sturtevant Richmont Digital Wrench to positively confirm that all of the tightening’s have been completed before the Counterweight can be installed.
Air Power’s Engineering Team, Michael John and Jesse Bryant, designed a “Lifting Sling Lock” device that will not release the lifting sling for the counterweight until the Tightening’s are complete – a Poke Yoke control to insure safety. This “Lifting Sling Lock” is utilized in conjunction with the I/O output of the Ingersoll Rand QX and the STR Digital Wrench, thus eliminating the safety hazard of a dropped counterweight. The Lifting Sling Lock will only unlock once all tightening have been positively confirmed, removing a safety hazard and improving overall production quality.
One of the main causes of injury in a manufacturing facility is due to lifting heavy objects. In this case study, Air Power helps a customer eliminate the risk of injury with an Ingersoll Rand custom monorail lifting system.
A local machinery manufacturer has had issues finding a suitable solution to include as part of their OEM machinery builds. They had a history of using electrical hoists and I beam trolleys which have not been well received by their end-users. The previous offerings by others were hard to maneuver and difficult to position the load for final placement.
Air Power Solution
Air Power proposed an Ingersoll Rand Zimmerman rail system, which are easily adaptable, cost-effective and easy to use. We designed a system for them that included 4 individual monorails with rigid mount hanger kits to increase clearance and ZAW air balancers with pendant controls for load lifting and proper part positioning. The solution allows each of the 4 sides of their machine to be covered from end to end.
The proposed solution provided the necessary benefits including:
- The ZRA1 monorails utilized minimum push/pull forces, allowing ergonomics on the operator and ease of use.
- For future integrations, the individual monorails provide an easily adaptable solution, should the OEM design change over time.
- The aluminum profile ZRA1 provided a reduction in solution weight.
- The ZAW air balancers allow the end-user to position the load close to its final destination then use the “float” of the balancer for final (and exact) placement of the part; further enhancing the user experience.
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.