Sturtevant Richmont Advanced Torque Systems Error proofing your customers assembly process – for...
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Transcript of Sturtevant Richmont Advanced Torque Systems Error proofing your customers assembly process – for...
Sturtevant RichmontAdvanced Torque Systems
Error proofing your customers
assembly process – for mutual profit!
Or, “No more misteaks!”
June 21, 2007
How many times . . .
• Has your customer said:
– “We missed a fastener.”– “It’s loose!”– “We overtightened it.”– “Which fastener did I leave off at?”
These statements are a sales opportunity.
– Every time this happens your customer lost money.
– The customer will have documented these and their costs.
– Eliminating them provides a sale and a documented savings!
What they need is called“Error-Proofing”.
• Error-Proofing is the application of designs, products and procedures that reduce the probability of error occurrence.
• Error-Proofing applies to simple and complex processes at many levels.
Error-Proofing & Torque Control• When the concepts of Error-Proofing are
applied to torque control in assembly operations, there are several levels of application.
• The more error-proof the process, the more likely the process will produce high-quality products reliably. AKA: “No more misteaks!”
Error-Proofing Levels in Assembly Torque Control
Building the pyramid!
Periodic Torque Tool Calibration – The Base
• Inaccurate tools invite error.• This means that regardless of the torque tools used,
periodic calibration is essential to an error-proof process.
Base In Place.
Interim Torque Tool Tests –A Strong Step Up.
• Tools can and do go out between calibrations.
• Interim tests, such as at the start of each shift, reduce the probability of this error occurring and save money.
Added Protection.
Standard Torque Tools –The Most Rudimentary Method
• Standard torque tools afford some process protection.
• Human error in their application remains possible.
Advanced Torque Systems –A BIG Step Up!
• Advanced torque systems address operator error directly, dramatically reducing the chance of affecting the process and product.
Advanced Torque Systems –Two Different Approaches
• Advanced torque systems use either attribute (Good/Bad) or variable (numeric) data to provide immediate feedback to the operator and the line.
• Either approach can provide a large reduction in errors.
Advanced Torque Systems –Attribute Approach
• Attribute systems (Accept/Reject) use communicating torque wrenches and base units to provide feedback to the operator and the line.
Advanced Torque Systems –Attribute Approach 2
• These systems communicate directly with the line via PLC communications.
• This integrates the error-proofing improvement with efficient line control.
Advanced Torque Systems –Variable Data Approach
• These systems give digital numeric torque data on each use to other processors to provide control.
• They also provide absolute proof of conformance.
Advanced Torque Systems –Variable Data Approach 2
• These systems can be applied as near real time systems (1/2 second delay) or batch systems (collect data, upload later).
The Fastener Installed.
Joint Auditing –The Last Step
• Joint auditing is simply performing periodic checks on the effectiveness of the process by testing the residual torque on the fasteners after assembly.
Joint Auditing –Part 2
• The data is collected as either attribute data or variable data.
• The amount of auditing needed depends upon the process and tools used in torque application!
Pyramid Complete.
Process Costs –The Real Improvement Driver
• Bottom line - the ultimate job of the process is to make a profit for the company.
• The lower the ongoing process costs, the more money the customer makes.
• Error-proofing lowers your customers ongoing costs and increases his profit - making you a most valuable distributor!
Process Costs –Part 2
• Ongoing costs are a greater determining factor in profitability than equipment acquisition costs.
• This is why many firms spend $15K+ for an advanced torque system instead of $300 for a standard tool.
Process Costs –Part 3
• When rework, repair, and warranty costs are reduced, the payback time for an advanced system is short.
• Since advanced systems allow less-frequent joint audits, the payback time becomes even shorter.
Process Cost Reduction –The Key to More Sales!
• Every engineer and every department manager wants to reduce their costs.
• If you look at their processes from a cost perspective, you will find where the opportunities lie.
Summary• Your customers need to reduce their ongoing costs to
improve their profitability.
• Error-proofing the assembly process dramatically reduces their ongoing costs.
• As an S/R ABD Distributor you have available the products that can make a large reduction in your customers process costs via error-proofing.
• Applying a cost perspective in your analysis of the customers needs will increase your sales!