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Smart Factory

From Electric Tools to Smart Tools: The Power of Data

7 minute(s) to read March 13, 2025

Electric tools offer a degree of control, making them an asset in many operations. However, as industry demands evolve, manufacturers often require deeper insights, improved traceability, and greater flexibility to refine their processes. To become a Smart Factory, leveraging data is essential. Digitized operational data unlocks new levels of efficiency. Our smart tools not only extend beyond basic functionality, but also provide greater control by delivering enhanced insights, unmatched precision, and the adaptability needed to elevate your operations. 


Efficiency


Advanced tightening programs

Smart tools revolutionize efficiency by enabling multiple tightening programs within a single device, eliminating the need for multiple tools dedicated to different torque ranges. This not only simplifies tool management but also ensures the correct torque is consistently applied, reducing reliance on time-consuming manual double checks. By streamlining processes, smart tools significantly cut down on the time spent per tightening, enhancing overall productivity.


Error-proofing

Programmable tightening strategies do more than just speed up operations—they provide real-time monitoring and control over angle limits. Defined final torque parameters minimize the risk of over-tightened or under-tightened bolts, preventing costly recalls. Advanced tightening strategies further refine the assembly process by monitoring screw seating, reducing variability, and enhancing consistency. Features such as Forced Order and Batch Programming ensure that every tightening is completed in sequence according to production requirements, allowing potential issues to be identified and resolved before they progress further down the line.


Ergonomics

Designed with the operator in mind, smart tools focus on reducing fatigue while improving efficiency. Intuitive Human-Machine Interfaces (HMIs), visual status indicators, and haptic feedback provide real-time guidance, enhancing usability and reducing cognitive strain. Additionally, our Avantguard solution offers step-by-step operator guidance, further simplifying complex tasks. To take ergonomics a step further, our range of low-reaction smart tools minimizes strain on operators, promoting long-term comfort and usability in demanding work environments.


Traceability


Data collection

With smart tools, data collection on tightening operations is instantaneous and continuous. Every critical detail is logged, from when the operation was performed to who executed it and how it was carried out. Tool location tracking ensures tools are used only in designated areas while also enabling quick and easy location identification. Real-time insights allow for immediate issue detection, preventing disruptions before they escalate, enabling proactive rather than retrospective corrections. 

Beyond compliance, collected data unlocks opportunities for continuous learning and process optimization. With data-driven insights, operations are always improving and staying ahead of the curve.


Instant feedback

Clear OK/NOK status indicators on the tool’s HMI provide instant feedback, allowing operators to quickly assess the tightening status. Additionally, all tightening data is stored at the part or VIN level, facilitating future investigations and ensuring compliance tracking. Furthermore, with digitized data, traceability becomes effortless, removing the need for tedious manual record-keeping, which is prone to loss, damage, and errors.   


Flexibility


Line balancing made easy

In today’s fast-paced manufacturing landscape, product mixes shift rapidly as customers demand increasing levels of customization. To keep up, line balancing must be seamless and efficient. Smart tools enable quick and precise line rebalancing, ensuring adaptability without unnecessary delays. Minimize tool downtime by swapping in pre-configured replacements whenever needed, whether due to shifting production requirements or unexpected tool failures. With smart tools, manufacturers gain the versatility to adapt to evolving production demands, ensuring agility in a dynamic environment.


Going cordless for greater mobility

Experience unrestricted mobility with our range of battery-powered smart tools, eliminating tripping hazards and expanding your operational reach. They say the sky's the limit, but for you, even the walls of the factory are no longer a barrier. Take manufacturing and maintenance wherever needed with portable, battery-operated smart tools. 

With ToolsControl, our virtual controller station, there's no need for space-consuming physical controllers. Everything is managed virtually. The software-based system moves the controller function off physical hardware, giving you a more flexible, streamlined, and efficient tool management solution. Our Tensor IxB smart tool range goes a step further, with an integrated controller eliminating the need for an external controller. 


Maximize uptime with predictive maintenance

Collecting data is only the beginning, what one does with the data is equally important. Smart tools analyze operational data in real-time, identifying trends and proactively detecting potential issues before they lead to failures. Our predictive maintenance solution, ALTURE Maintain, ensures tools undergo servicing at the optimal time, neither too soon nor too late, preventing unexpected breakdowns and minimizing prolonged downtime. By scheduling maintenance strategically, operations remain uninterrupted. 

Smart Integrated Assembly

Your roadmap to a Smart Factory

Smart Integrated Assembly - Complete integrated ecosystem without text

By integrating smart tools with our ecosystem of software solutions and services, we enable scalability, allowing your operations to adapt effortlessly to changing production demands. Smart Integrated Assembly is our structured, five-step approach designed to seamlessly guide you through the transition to a Smart Factory.  We provide comprehensive support at every stage, from the joint level to factory level, ensuring a smooth and efficient evolution. By following this roadmap, manufacturers in Industry 4.0 can unlock the full potential of Smart Factories. 


Efficiency, Traceability, & Flexibility

As data flows through the factory, it is now becoming clear that what you do with the data is just as important as having it. If you perceive that enhanced efficiency, traceability, and flexibility could benefit your operations, our smart tools are the solution. Our Smart Integrated Assembly concept, enabled by data, provides a structured path toward a fully connected Smart Factory, helping manufacturers achieve the precision, control, and adaptability they require.

Are you ready to take the step to becoming a Smart Factory? Contact us to know what smart tools can do for you. 

Smart Integrated Assembly
Smart Integrated Assembly, our roadmap to transforming your operations into a Smart Factory
 
Smart Integrated Assembly, our roadmap to transforming your operations into a Smart Factory
Smart Integrated Assembly, our roadmap to transforming your operations into a Smart Factory
Smart Integrated Assembly White Paper
Smart Integrated Assembly White Paper
Smart Integrated Assembly – Industrial Manufacturing in the era of Industry 4.0 and beyond
 
Smart Integrated Assembly – Industrial Manufacturing in the era of Industry 4.0 and beyond
Contact us
Contact us
Learn more about how Atlas Copco can optimize your assembly line.
 
Learn more about how Atlas Copco can optimize your assembly line.

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