Manufacturing defects are expensive and removing these errors prior to equipment leaving the production floor is an achievable result when utilizing the proper assembly equipment. In the below case study, implementing proper tooling resulted in a significant reduction in warranty, service work, and recalls.
A global manufacturer of grain and sugar cane harvesters located within the Southeastern United States.
Challenge: Warranty, Service Work, and Recalls
During the manufacturing process; a sub assembly cell was responsible for proper tightening of fluid hose clamps. The specified torque and angle of these hose clamps was not being achieved by current in plant tooling. This failure was a direct result of joint conditioning and relaxation associated with the hose clamp tightening process. In order to confirm clamps were properly tightened a manual QC measure was put into place in order to catch the issue prior to units leaving for in field use. However, manual processes are reliant on operator execution and improperly tightened units continued to leave the production floor incorrect. This issue was exaggerated once units reached final destinations for use within the field, as inadequate torqued hose clamps, were continuing to loosen causing costly warranty, recall, and infield technician repairs.
Air Power’s Solution
In partnership with the customer, Air Power implemented an Ingersoll Rand QX Precision fastening System. The hand held, battery operated, transducerized tooling solution provided an accurate final torque, while providing the operators with tightening status feedback, actual torque values, and 1,200 rundowns of tightening data for review. A proper torque strategy was developed allowing the hose clamp to be properly torqued, relaxed (conditioned), then final torqued; all within a single trigger pull delivered by the operator. The need for a manual QC measure was removed as the torque data was verified, tracked, and retained by the manufacturing facility for spot check and validation.
Currently, thirteen (13) right angle tools are being utilized within this facility allowing production to reach new heights of process control. Proper tightening of the hose clamps, torque data retention, and date/time stamping have reduced warranty, service work, and those costly infield technician repairs. The Air Power solution ensures that product leaving the production floor is assembled correctly, the first time.
Taking total control of your fastening process doesn’t have to be complicated. Ingersoll Rand’s comprehensive QX Series family of fastening systems deliver simple, flexible and capable solutions for all of your assembly requirements. No matter the industry or application, you can count on Ingersoll Rand as a trusted partner to help you get the job done right!
The innovative QX Series of cordless precision fasteners is a revolutionary step for your entire facility – one that shows how a smarter tool can improve process control, operator comfort and data communication. In a single, affordable package, this tool puts you in control by helping to increase productivity, lower costs and ensuring a high-quality product at the end of your production line.
The QX Series family of tools consists of:
- QX ETS
Currently, there are three (3) quick, easy, and effective methods in which to program a QX tool for deployment within your manufacturing process.
1.Programming with the Insight Connect App:
- The INSIGHT™ Connect app will help you stay productive, mobile and in control of your fastening process. It programs any Ingersoll Rand® QX Series™ tool without the need for additional technical training, special software, plant network permissions or a laptop computer. Working from a smartphone or tablet, operators can use the app to quickly program the torque and angle control configurations on these closed-loop, transducerized tools.
- Once installed, the INSIGHT™ Connect app can operate offline, so it functions in large facilities or other locations where Internet signal loss may be a problem, reducing downtime and maximizing ease of use. You can quickly perform key tasks with your mobile device, including:
- Torque + angle
- Back-up and restore tool settings
- Retrieval of tool logs and the ability to send via email for post-processing
- Review audit logs
2. Programming from the back of the tool
Or reference the below video (some of the menu options have changed since this video was posted by Ingersoll Rand in 2017 – but the overall flow and understanding remain unchanged)
3. Programming utilizing the Ingersoll Rand ICS Software
Taking total control of your fastening process doesn’t have to be complicated. The Ingersoll Rand QX Series™ family of fastening systems deliver simple, flexible and capable solutions for all assembly requirements. No matter the industry or application, you can trust Ingersoll Rand to help you get the job done right. Ingersoll Rand® has released the QX Series™ Ergonomic Tightening System (ETS). With ETS, reducing the torque reaction of the fastening process doesn’t have to be complicated. The ergonomically-enhanced motor control algorithm minimizes torque reaction to protect workers from injury. When tightening, ETS delivers short bursts of energy into the fastener, enabling the operator to safely stay in control of the tool.
What is ETS?
QX + ETS delivers all the performance & control features of the standard QX Series ™ precision fastening tools, with an improved ergonomic benefit. QX + ETS incorporates an ergonomically enhanced motor control algorithm that significantly reduces the average amount of force experienced by the operator during the tightening process.
Why choose ETS?
When ETS is Active, the operator’s arm movement is limited to a series of smaller movements instead of one large movement. This enables the operator to stay in control and in the ‘power zone’, reducing the chance for injury caused by quick, excessive movement.
QX + ETS reduces average reaction force experienced by the QX Series user by up to 63%!
Air Power, Inc. presents a demonstration of Ingersoll Rand’s Advanced Tightening System by Kyle Crawford