As a manufacturer, nothing is more frustrating than rework due to warranty claims. Errors made on the line lead to a plethora of issues, including increased cost, downtime, and, in some cases, a negative effect on your reputation. It is the goal of many manufacturing facilities to reduce or even eliminate errors made on the line. Achieving zero defects ensures you and your operators spend less time fixing products, thus saving your operation money and improving uptime.
When a major lock manufacturer came to Atlas Copco looking for a solution that would reduce or even eliminate the occurrence of errors made on the line, we knew just what they needed. Our solution: a station managed by our MicroTorque Focus 6000 (MTF6000) controller paired with an ETD M 250 low torque screwdriver. Keep reading to discover how we were able to reduce their warranty claims by 90% with this solution.
But first: What is the MicroTorque Focus 6000?
Smart, connected tools are the future of manufacturing, and Atlas Copco’s MicroTorque Focus 6000 controller makes connecting your tools and collecting data even easier. This controller enables users to customize their strategy for any type of screwed joint and configure multiple tightening programs in the right sequence for your process, sometimes eliminating the PLC. The user-friendly software interface, along with the power to easily analyze and configure improvements, makes complex processes simple.
Now, our customer’s situation
Our customer was working hard to produce quality locks but was facing warranty claims for the past year due to missing fasteners or loose parts. This was frustrating to both them and their customers. Not only was the quality of the locks this manufacturing plant produced not consistent, but they were also dealing with low productivity levels and extra costs due to rework and scrap.
The solution
Understandably, our customer wanted to be more proactive by reducing or eliminating the number of defects and errors made on the line. For us, the solution was clear: Incorporating a MicroTorque Focus 6000 controller paired with an ETD M 250 low torque screwdriver into their assembly. This was an obvious solution because it would allow them to:
- Collect data and monitor stations
- Utilize Batch Sequence and operator guidance capabilities
- Easily program and perform trace analyses
- Hook up smart jigs and integrate them into the station for no-fault assembly
- Use it in multiple stations
What does all this mean for our customer? Well, since they are now able to collect data, monitor stations, utilize Batch Sequencing, and benefit from the operator guidance capabilities, they will be able to monitor for patterns in tightening inconsistencies and ensure that operators are producing quality locks free from errors or defects. Ultimately, this would improve their uptime and quality and reduce the occurrence of errors made during production. Now, their operators will be guided through the application and alerted if/when an error occurs.
Why choose Atlas Copco?
At Atlas Copco, we strive to provide the most efficient offerings on the market. No matter your needs, we have the solutions that will best fit your applications. In this customer's case, we successfully provided them with smart solutions that improved their uptime and quality while reducing the occurrence of defects made during assembly.
Does your operation have a quality issue that needs resolving? Contact Atlas Copco and talk with one of our experts about the products and solutions that can help.