As the digital age marches forward, electronics assembly is in high demand. This global electronic contract manufacturer customer has locations around the world designed to meet the unique needs of every kind of assembly. In one of its US facilities, they contract manufacture servers and routers for industry-leading companies. Because some of the boards being assembled cost upwards of a million dollars apiece, quality workmanship at every level of assembly is essential—down to every turn of a fastener. The need for capturing data about the manufacturing process and ensuring zero quality issues is paramount to success in the industry. For them, Mountz tools are an essential part of making that possible.
Manufacturing Challenges – Torque Control & Ensuring Compliance
- Document the torque applied to every screw
- Quality workmanship at every level of assembly eliminating user error
- Incorrect torque applied during the tightening process
- Operator selecting the incorrect bit
Torque Solutions Applied
- Implementation of data capture solutions to document quality compliance of every screw tightened
- Error-proofing the fastening process
- Deploying sensor-based technology to ensure the usage of the correct bit
- Programming key parameters and sequence to control the tightening process
- Torque control system with the ability to store multiple preset torque values
- Automatically adjust preset torque setting for the application using a bar code system
To ensure the right torque is achieved with every fastener tightened, Mountz provided the contract manufacturer with an MD-Series automation torque control system for precision accuracy data collection.
However, guaranteeing every operator only used the right bit required the development of a custom solution. The answer was the Bit Socket Tray with sensors to detect colors and different color tape wrapped around each bit. The tray connects directly to the torque control system.
When a board arrives at the assembler, they scan the bar code on the assembly base. This indicates which color bit they should take from the four-position tray. When the bit is attached, the tool is automatically set for the correct torque specs. If the incorrect bit is selected or no bit is attached, the tool has no power, preventing assembly errors.
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Data capture has been implemented throughout the assembly line. In addition to limiting errors in assembly, the new solution also helps ensure immediate access to the right bit at the right time.
At Mountz Inc., we understand the flexible nature of contract manufacturing. As such, we build our torque tools to deliver the accuracy your product needs without sacrificing the speed that keeps your operation competitive. Shop our products now. To inquire about price, request a quote. To ask a question, contact us today. To request a demonstration, schedule an appointment.