Flat-pack furniture famously exported by Scandinavia offers practical lessons about the importance of assembly line ergonomics. Assembling the furniture doesn’t seem difficult, especially if you have your own power tools, along with the small disposable screwdrivers and hex keys that come with the furniture. However, once you have it assembled, you may find your hands hurting from holding the screw gun, your shoulder twinging from holding a power tool out, and your back aching from bending over. You may have a few screws that protrude and are too stripped out to be driven in and some left-over screws that you only hope were included as extras.
The furniture itself is very much like what is put together on the assembly line. It is made from engineered pieces cut by machines, and all that remains for you to do is assemble it. The end product results from the ad-hoc assembly process it was put together with, and the nagging aches result from ignoring basic ergonomics. If they are ignored on your company’s manufacturing room floor, the results will be employee injuries and an unreliable, substandard product. Therefore, assembling reliable products requires fastening on-spec with quality tools at workstations that are comfortable to work at for long periods.
The Importance of Quality Torque Tools and Aids on the Assembly Line
Torque is the force that determines whether screws, bolts, and other fasteners hold together. It is a specific measure of rotational force determined by multiplying the force applied by its distance from the application point. If too much torque is applied, the components being held together may become deformed, cracked, or broken. The fastener itself can be stripped or sheared through, too. Alternatively, if too little torque is applied, then vibrations or daily use can cause fasteners to come loose. Reliable products depend on being tightened to the exact required torque specification. However, the repeated motions associated with tightening fasteners can take a physical toll on employees.
You must consider assembly line ergonomics to prevent workplace injuries and ensure a quality product. Ergonomics is the study of people’s efficiency in their working environment. However, it is generally understood to mean laying out workstations—whether in the office or on the manufacturing floor—to allow for movements that are efficient, comfortable, and prevent injury. In an office workplace, this is a matter of considering tables, chairs, and monitors. It is a little more challenging on an assembly line where components and torque tools are heavier, and the movements are much more significant in scope. Stage-by-stage assembly line design requires production aids to improve ergonomics.
Improving Assembly Line Ergonomics With Torque Tools and Production Aids
If you find your arm sore after assembling a piece of flat-pack furniture or misplaced fasteners, then you should clearly grasp the challenges facing assembly line workers. Providing a workstation with all the necessary tools and components is an essential first step in improving assembly line ergonomics, but it is only a first step.
Workstations for the assembly of light industrial components like electronics not only need torque screwdrivers to ensure that screws are fastened to spec but also devices like gliding torque arms and telescoping torque arms to take the weight of the tools off of employees while ensuring they maintain control of the tool. These also allow precise control of the angle and force that the bit in the torque tool meets the screw with, preventing stripped heads and cross-threading. Screw presenters position the fasteners needed for assembly one by one at a fixed pick-up point. They remove the need to grab a single fastener from a bin, saving time and further reducing the likelihood of misalignment. A screw counter can be used to ensure that all needed fasteners are used and that the assemblies are not moved farther along the production line if they’re missing screws.
Heavier industries that require more flexibility and speed than is possible with a fixed torque arm can improve their assembly line ergonomics with a tool balancer. These devices consist of a tool attached to a cord or hose, while a pulley within provides tension that counterbalances the weight of the tool. They allow powered assembly tools like electric screwdrivers, air screwdrivers, and pulse tools to be wielded with a high degree of control over their angle and positioning, ensuring that fasteners are driven without cross-threading, stripping, or errors.
Producing quality products from an assembly line depends on your employees’ motivation and skills. One of the major benefits of assembly-line ergonomics is keeping them productive and pain-free. Reliable torque accessories are important in keeping your employees focused on their work instead of discomfort in their hands and shoulders.
Mountz EZ-Glider torque arms are designed to improve safety, production and quality control during assembly process. To see our full range of products, shop our store. Contact us anytime to ask a question. To inquire about price, request a quote. If you’d like to see our equipment in person, schedule an appointment. To get the latest torque-related news, follow us on LinkedIn.
