Pneumatic tools have long been the go-to choice in manufacturing. But as Industry 4.0 advances, manufacturers face growing demands for traceability, data-driven decision-making, and greater operational flexibility.
Enter smart electric tools — designed to optimize efficiency, improve accuracy, and boost overall productivity, all while enhancing the operator experience.
Air tools in focus
Manufacturers are increasingly prioritizing efficiency and sustainability, making it crucial to consider the broader energy impact of using compressed air systems necessary for pneumatic tools. Compressed air can account for a significant share of a plant’s energy costs, at times, up to 30%. Over time, air leaks in these systems can lead to energy losses of 20–30%, with even a small 1.5 mm leak adding up to €1,000 per year in energy inefficiencies. Air pressure fluctuations in compressed air systems can also affect pneumatic tool performance, leading to varying productivity and quality. Maintaining stable pressure, ensuring consistent tool performance, and eliminating leaks require regular maintenance and planning for downtime—all of which depend on accurate manual data.
However, pneumatic tools play an integral role in certain operations and will continue to do so, manufacturers looking for deeper operational insights to channel data-driven decision-making may find smart electric tools to be a compelling alternative.
Shift to smart electric tools
Smart electric tools transform the way manufacturers manage processes, delivering greater precision and control. By integrating these tools, manufacturers can achieve up to 88% energy savings, cut CO₂ emissions by 4 tons per tool, and save approximately €300 per tool annually.*
*The calculation is based on the Atlas Copco Group Product carbon footprint tool, which is an ISO 14067 certified tool.
Beyond energy efficiency, smart electric tools enhance operational flexibility by integrating real-time data analysis and advanced tightening programs that accommodate multiple torque settings. In contrast, standard electric tools are limited to a single torque setting and lack connectivity functionalities. By harnessing Industry 4.0 capabilities, smart electric tools enable seamless communication across the plant, allow every stage of the assembly process to be optimized.
Building a Smart Factory with smart electric tools
A Smart Factory is built on complete connectivity and traceability. Smart electric tools make this possible with real-time data collection and automated reporting, reducing reliance on manual record-keeping and minimizing the risk of inconsistencies or data loss. With full traceability of each tightening, manufacturers can reinforce accountability and enhance quality assurance.
Our smart electric tools give you greater control over your operations by ensuring:
Quality & Error-proofing: Consistent fastening is critical in manufacturing. Our smart tools can monitor torque and angle in real-time, reducing the risk of over-tightening or under-tightening. Immediate operator feedback minimizes errors and rework, leading to improved first-time-right rates and enhanced product quality. Intelligent error-proofing mechanisms enable manufacturers to refine their processes and achieve higher levels of precision.
Productivity & Flexibility: Our smart tools support multiple torque settings within a single tool, reducing the need for multiple pneumatic tools and streamlining operations. This not only optimizes task times but also minimizes the reliance on manual inspections, leading to a more efficient production process with lower maintenance demands and reduced downtime.
Operator ergonomics: Manufacturing environments can be physically demanding, and our smart tools offer ergonomic advantages that enhance worker comfort and safety. Compared to pneumatic tools, they generate less vibration and noise, reducing strain on operators and improving overall workplace conditions. Cordless, battery tools further enhance mobility, eliminate trip hazards, and provide greater flexibility, extending usability beyond the plant floor.
Smart Integrated Assembly: connecting the dots
Atlas Copco’s vision for a Smart Factory is about more than just individual tools. It is about creating a fully connected ecosystem. Smart Integrated Assembly is our structured, 5-step approach to transforming manufacturing, from the very first joint fastened to the complete connectivity of the factory. With Smart Integrated Assembly, we help you seamlessly connect the dots across your operations.
Why shift now?
Manufacturing is evolving rapidly with Industry 4.0, bringing new demands for quality, traceability, and efficiency. As operations become more data-driven, having the right tools can make all the difference. Smart electric tools not only enhance precision and productivity but also provide real-time insights that drive continuous improvement. Embracing these innovations today can help manufacturers stay agile and competitive in an increasingly digital world
Capture your data, transform it into deeper insights, and take your operations to the next level with smart electric tools.