Sturtevant Richmont Advanced Torque Systems Error proofing your

Sturtevant Richmont Advanced 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 $15 K+ 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!